Honda BF115 D Outboard motor Owner's Manual

31ZX1600

00X31-ZX1-6000

EM3

AH

英

N HC 300.2010.05

Printed in Japan

Includes US and Canadian Models

PANTONE 288 CVC DIC F101 BLACK

BF115D

10/04/13 15:06:37 31ZX1600_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.

2010 Honda Motor Co., Ltd.

− All Rights Reserved

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.

10/04/13 15:06:42 31ZX1600_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.

Best Wishes,

Honda Motor Co., Ltd.

INTRODUCTION

1

10/04/13 15:06:52 31ZX1600_003

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

10/04/13 15:06:55 31ZX1600_004

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

. 7

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

. 7

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

. 9

CONTROLS AND FEATURES ..................................

. 12

CONTROL AND FEATURE IDENTIFICATION

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

. 12

COMPONENT AND CONTROL LOCATIONS ....

. 13

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

. 17

Side-Mount Type

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

. 17

Emergency Stop Switch Clip and Emergency

Stop Switch .......................................................

. 17

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

. 18

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

. 19

Panel-Mount Type

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


. 20

Stop Switch .......................................................

. 21


. 22

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

. 23

CONTENTS

Top-Mount Type

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

. 24


Stop Switch .......................................................

. 24


. 25

Fast Idle Button

Common Controls

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

. 27

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

. 28

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

. 29

Manual Relief Valve

Tilt Lock Lever

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

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

. 29

. 29

TRL (Trolling) Control Switch

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

. 30

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

. 30

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

. 30

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

. 31

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

. 31

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

. 31

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

. 31

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

. 32

NMEA Interface Coupler ......................................

. 32

3

10/04/13 15:06:59 31ZX1600_005

CONTENTS

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

. 33

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

. 33

Malfunction Indicator ...........................................

. 33

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

. 34

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

. 34

Cooling System Indicator

OTHER FEATURES

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

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

. 35

. 35

Water Separator Buzzer

Rev Limiter

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

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

. 35

. 36

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

. 36

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

. 36

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

. 37

ARE YOU READY TO GET UNDERWAY?

.........

. 37

IS YOUR OUTBOARD MOTOR

READY TO GO?

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

. 37

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

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

. 39

. 39

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

. 39

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

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

. 40

. 41

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

. 41

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

. 44

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

. 46

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

. 49

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

. 49

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

. 50

GEARSHIFT AND

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

. 51

STEERING

CRUISING

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

. 52

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

. 53

Trolling Speed Control .........................................

. 55

TRIM TAB ................................................................

. 56

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

. 56

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

. 57

4

10/04/13 15:07:02 31ZX1600_006

CONTENTS

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

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

. 59

. 59

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

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

. 60

. 61

SPARE EMERGENCY STOP SWITCH CLIP

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

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

. 61

. 62

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

. 64

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

. 65

ENGINE COVER REMOVAL AND

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

. 65

Engine Oil Level Check

Engine Oil Change

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

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

. 66

. 66

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

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

. 68

. 69

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

. 70

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

. 72

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

. 75

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

. 76

Fuel Filter Inspection and Replacement

Water Separator Inspection and Service

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

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

. 77

. 80

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

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

. 82

. 82

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

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

. 84

. 84

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

. 84

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

. 85

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

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

. 87

. 88

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

. 88

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

. 89

5

10/04/13 15:07:05 31ZX1600_007

CONTENTS

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

WITH OUTBOARD MOTOR

. 90

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

. 90

WITH OUTBOARD MOTOR

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

. 90

TAKING CARE OF UNEXPECTED PROBLEMS ....

. 91

ELECTRIC STARTER WILL NOT OPERATE .....

. 91

ENGINE WILL NOT START ..................................

. 92

HARD STARTING OR STALLS AFTER

STARTING ...........................................................

. 94

ENGINE OVERHEATS

FUSES

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

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

. 95

. 96

Electric Starter Will Not Operate ..........................

. 96

Battery Will Not Charge

Fuse Replacement

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

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

. 96

. 96

OIL PRESSURE INDICATOR GOES OFF AND

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

. 98

OVERHEAT INDICATOR COMES ON AND

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

. 99

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

. 101

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

. 101

SUBMERGED OUTBOARD MOTOR .................

. 101

TECHNICAL AND CONSUMER

INFORMATION .................................................

. 103

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

. 103

Serial Number Locations

Battery

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

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

. 103

. 104

Emission Control System Information

Star Label

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

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

. 104

. 107

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

. 109

CONSUMER INFORMATION

Honda Publications

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

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

. 110

. 110

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

. 110

Warranty Statements ...........................................

Distributor’s Limited Warranty ..........................

. 113

. 113

Emission Control System Warranty

Distributor’s Warranty

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

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

. 118

. 122

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

. 125

6

10/04/13 15:07:13 31ZX1600_008

IMPORTANT SAFETY

INFORMATION

The Honda BF115D outboard motor is 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 injuries or property damage can be prevented if you follow all instructions in this manual and on the outboard motor. The most common hazards are discussed in this chapter, 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

10/04/13 15:07:20 31ZX1600_009


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 contains poisonous carbon monoxide, a colorless, odorless gas.

Breathing carbon monoxide can cause loss of consciousness and may lead to death.

If you run the engine in an area that is confined, or even partly enclosed, the air you breathe could contain a dangerous amount of exhaust gas.

Never run your outboard inside a garage or other enclosure.

8

10/04/13 15:07:25 31ZX1600_010

SAFETY LABEL LOCATION

US, Puerto Rico, and US Virgin Islands Types


The label shown here contains important safety information. Please read it carefully. This 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

10/04/13 15:07:31 31ZX1600_011


Canadian Types

READ OWNER’S MANUAL

The label shown here contains important safety information. Please read it carefully. This 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.

10

10/04/13 15:07:34 31ZX1600_012

Canadian Types

Honda outboard motor is designed to give safe and dependable service if operated according to instructions.

Read and understand the

Owner’s Manual before operating the outboard motor. Failure to do so could result in personal injury or equipment damage.


11

10/10/08 14:17:57 31ZX1600_013

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model BF115D

Type LA LC XA XC XCA

Transom Height

20.0 in (508 mm)

25.0 in (635 mm)

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

Power Trim/Tilt

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: American, C: Canadian

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)

12

10/04/13 15:07:50 31ZX1600_014


COMPONENT AND CONTROL LOCATIONS

ENGINE COVER

SPARK PLUG

(under coil)

OIL FILLER CAP

JUNCTION BOX

(FUSES)

NMEA INTERFACE

COUPLER

ENGINE COVER

LATCH

STERN

BRACKET

MANUAL

RELIEF VALVE

ANODE

OIL LEVEL DIPSTICK

FLUSH PORT

CONNECTOR

COOLING SYSTEM

INDICATOR

ANODE ENGINE OIL

DRAIN BOLT

(inside cover)

ANODE

ANTIVENTILATION

PLATE

EXHAUST PORT/WATER

OUTLET PORT

TRIM TAB

PROPELLER

(optional equipment)

POWER TILT

SWITCH

TILT LOCK

LEVER

PRODUCT

IDENTIFICATION

NUMBER

GEAR OIL LEVEL

CHECK SCREW

COOLING WATER

INTAKE PORT

GEAR OIL DRAIN/FILL SCREW

13

10/04/13 15:07:57 31ZX1600_015


Remote Controls (optional equipment)

Side-Mount Control Type

GEARSHIFT/THROTTLE

CONTROL LEVER

NEUTRAL RELEASE LEVER

POWER TRIM/TILT

SWITCH

SPARE EMERGENCY

STOP SWITCH CLIP

BUZZER

(inside)

CONTROL LEVER

FRICTION ADJUSTER

EMERGENCY STOP

SWITCH LANYARD

Panel-Mount Control Type


CONTROL LEVER

NEUTRAL RELEASE

LEVER

INDICATORS

(Oil pressure, Overheat,

Alternator, Malfunction)

FAST IDLE

LEVER

IGNITION

SWITCH

IGNITION

SWITCH KEY

EMERGENCY

STOP SWITCH

POWER TRIM/TILT

SWITCH

FAST IDLE BUTTON

Control Panel

(for Panel-Mount Type)

BUZZER

EMERGENCY STOP

SWITCH CLIP

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

INDICATORS



EMERGENCY

STOP SWITCH

14

10/04/13 15:08:03 31ZX1600_016

Top-Mount Type

(Single Outboard Motor Type)


CONTROL LEVER


(Dual Outboard Motor Type)


CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

POWER TRIM/TILT

SWITCH

POWER TRIM/TILT

SWITCH (LEFT)


Control Panel

(Top-Mount Single Type)

BUZZER

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

INDICATORS



EMERGENCY

STOP SWITCH


(for Top-Mount Dual Type)

15

10/04/13 15:08:11 31ZX1600_017


Instruments


Tachometer Digital Speedometer Trolling Control Switch Panel

Trim Meter Digital Tachometer

TRL (Trolling) CONTROL SWITCH

16

10/04/13 15:08:20 31ZX1600_018

CONTROLS

Side-Mount Type

Ignition Switch

O F F

O N

START

IGNITION

SWITCH

The ignition switch controls the ignition system and the starter motor.


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 engine will not start unless the gearshift/throttle control lever is in

the N (neutral) position (p.

41 ) and

the emergency stop switch clip is in the emergency stop switch.

Turning the ignition switch to the

OFF position stops the engine.

Emergency Stop Switch Clip and

Emergency Stop Switch

EMERGENCY STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

17

10/04/13 15:08:26 31ZX1600_019


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

(Personal Flotation Device).

When used as described, the emergency stop switch clip and emergency stop switch 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).

SPARE SWITCH CLIP

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.

18

10/04/13 15:08:34 31ZX1600_020

T H R O

F (FORWARD)

N (NEUTRAL)

30° 30°

SHIFT SHIFT

T T L E O P E

M

N 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


Fast Idle Lever

FAST IDLE LEVER

MAXIMUM


CONTROL LEVER

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 adjusts the operating resistance of the control lever. Refer

to p.

52 .

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

Use the fast idle lever to accelerate engine warm-up after starting the engine. Do not use the fast idle lever when starting the engine.

See page 43

for engine warm-up instructions.

19

10/04/13 15:08:43 31ZX1600_021


N (neutral)

MAXIMUM FAST IDLE

LOWEST

POSITION

FAST IDLE LEVER

The fast idle lever allows you to increase the idle speed only when the control lever is in the N (neutral) position. Place the fast idle lever in its lowest position to cancel the fast idle and return the control lever to normal operation.

Panel-Mount Type


ON

START

OFF

IGNITION

SWITCH






44 ) and




20

10/04/13 15:08:49 31ZX1600_022




EMERGENCY

STOP SWITCH




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



EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

21

10/04/13 15:08:57 31ZX1600_023



Lever


CONTROL LEVER

T H R O T T L

F (FORWARD)

35°

N (NEUTRAL)

35°

SHIFT

SHIFT

E O P E N I N

M

G

I N I M U M

R (REVERSE)

M I N I M U M


MAXIMUM

NEUTRAL

RELEASE

LEVER

MAXIMUM

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




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.


CONTROL LEVER

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

to p.

52 .


22

10/04/13 15:09:04 31ZX1600_024

Fast Idle Button


Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.

See page 45



F (forward)

CONTROL

LEVER

Push

N (neutral)

R (reverse)

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

Return the control lever to N

(neutral) position to cancel the fast idle operation.

P u l l u p

NEUTRAL

RELEASE

LEVER


The fast idle button allows you to increase the idle speed without engaging the drive gears. Move the control lever forward or reverse after pushing in the fast idle button to increase the idle speed.

23

10/04/13 15:09:13 31ZX1600_025


Top-Mount Type


START

ON

OFF

IGNITION

SWITCH





47 ) and






EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP


EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

24

10/04/13 15:09:19 31ZX1600_026




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


Lever

SINGLE TYPE


CONTROL LEVER

DUAL TYPE


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





CONTROL LEVERS

25

10/04/13 15:09:25 31ZX1600_027




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

p.

52 .


N (NEUTRAL)

F (FORWARD)

35°

SHIFT

35°

SHIFT

R (REVERSE)

M I N I M U M


M I N I M U M


MAXIMUM

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

26

10/04/13 15:09:32 31ZX1600_028

Fast Idle Button

F (forward)

N (neutral)


R (reverse)

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

Return the control lever to N

(neutral) position to cancel the fast idle operation.

CONTROL

LEVER


Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.

See page 48


Push


The fast idle button allows you to increase the idle speed without engaging the drive gears. Move the control lever forward or reverse after pushing in the fast idle button to increase the idle speed.

27

10/04/13 15:09:41 31ZX1600_029


Common Controls

Power Trim/Tilt Switch

(Side-Mount Type) (Top-Mount Type)

SINGLE TYPE

POWER TRIM/TILT SWITCH

CONTROL

LEVER

POWER TRIM/TILT

SWITCH

(Panel-Mount Type)

CONTROL

LEVER


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 outboard motor angle.

Trim the outboard motor to obtain the best performance and stability

(p.

53 ).

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

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

C O N T R O L

L E V E R S

28

10/04/13 15:09:51 31ZX1600_030

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

POWER TILT SWITCH

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.

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

Check that nobody is under the outboard motor before opening the manual relief valve. If the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

TILT LOCK LEVER

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 up 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.

29

10/04/13 15:10:01 31ZX1600_031


Engine Cover Latch TRL (Trolling) Control Switch


SWITCH

PANEL

Trim Tab

TRIM TAB

BOLT

UNLOCK

ENGINE COVER LATCH


The Trolling Control Switch is a rocker switch with UP and DN

(down) positions to adjust the trolling speed up or down in 50 RPM increments within the range of 650 to

900 RPM.

If you press and hold the TRL control switch while cruising with the throttle closed, the mode changes to

trolling mode (p.

55 ).

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

30

TRIM TAB

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.

64 ), steering effort is

equal in both directions.

10/04/13 15:10:15 31ZX1600_032

INSTRUMENTS

Trim Meter


Tachometer



Digital Tachometer


The trim meter indicates the relative 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.

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

Malfunction Indicator

Refer to the Operation Guide included with the Digital Tachometer for operation information.

31

10/04/13 15:10:26 31ZX1600_033


Digital Speedometer


NMEA Interface Coupler

NMEA2000 based information on engine speed, fuel consumption, and various warnings can be read by connecting to the motor with the interface cable (optional equipment).

Contact your dealer for more information.

Digital Speedometer includes the following functions.

Speedometer

Fuel Level Meter

Voltmeter

Tripmeter

Fuel Integration Meter

Fuel Economy Meter

Fuel Flow Meter

Water Separator Indicator

Refer to the Operation Guide included with the Digital

Speedometer for operation information.

32

NMEA INTERFACE COUPLER

(6 pin black)

10/04/13 15:10:39 31ZX1600_034

INDICATORS

The indicator lights come on and the buzzer sounds when you turn the ignition switch ON, allowing you to see that they are working. If an indicator does not light during this test, it cannot alert you if that system develops a problem. Have your

Honda Marine dealer check for burned-out bulbs or other problems.

Under normal conditions, the following occur when the ignition switch is turned ON:

1.

The ACG, Malfunction, Oil

Pressure, and Overheat indicators light.

2.

3.

4.

The buzzer will beep twice.

The Malfunction, Oil Pressure, and Overheat indicators will go out after the second beep.

The ACG indicator will go out after the engine starts.

5.

The Oil Pressure indicator will light again after the engine starts and will stay lit to indicate the oil pressure is normal.

Alternator (ACG) Indicator

(side-mount type)

BUZZER

(panel-mount/top-mount types)

ACG INDICATOR

(RED)

ACG INDICATOR

(RED)

BUZZER

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


Malfunction Indicator


MALFUNCTION

INDICATOR

(RED)

BUZZER


MALFUNCTION

INDICATOR

(RED)

BUZZER

When the engine control system detects an engine control system malfunction, the malfunction indicator turns on and the buzzer sounds at one-second intervals.

33

10/04/13 15:10:48 31ZX1600_035


Oil Pressure Indicator


OIL PRESSURE

INDICATOR

BUZZER


OIL PRESSURE

INDICATOR

(GREEN)

(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,

on p.

98

.

All models are equipped with a buzzer that sounds continuously 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


OVERHEAT

INDICATOR

(RED)

BUZZER


OVERHEAT

INDICATOR

(RED)

BUZZER

34

BUZZER

10/04/13 15:10:56 31ZX1600_036

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

, on

p.

99

.

All models are equipped with a buzzer that sounds continuously when the red light 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.

The cooling system indicator discharge port can also become plugged.


OTHER FEATURES

Water Separator Buzzer

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

WATER SEPARATOR

35

10/04/13 15:11:05 31ZX1600_037


Anodes Rev Limiter

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

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

If the rev 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

(outboard motor side)

PRIMING BULB

INLET END (tank side)

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.

40 ).

36

10/04/13 15:11:15 31ZX1600_038

ARE YOU READY TO GET

UNDERWAY?

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 underway. Know what to do in case of an emergency.

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 the operator or to the operator’s PFD.

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 pre-operation checks, be sure the ignition switch is in the OFF position.

37

10/04/13 15:11:26 31ZX1600_039

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.

38

Check the emergency stop switch for proper operation. Start the

engine (p.

, or

46

). Make sure the engine stops by pulling the emergency stop switch clip from the emergency stop switch.

Maintenance Inspection

Check the engine oil level (p.

66 ).

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.

83 ).

Check that the anodes are securely attached to the stern bracket and

the gear case (p.

82 ) and are not

excessively worn. The anodes help protect the outboard motor from corrosion.

Make sure the tool kit is onboard

(p.

61 ). Replace any missing items.

Check the fuel level in the fuel

tank (p.

75 ).

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.

80 ).

10/04/13 15:11:38 31ZX1600_040

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, do not start or run the engine in a confined or partly enclosed area. Your engine’s exhaust contains poisonous carbon monoxide, a colorless, odorless gas that can collect rapidly. Breathing carbon monoxide can cause loss of consciousness and may lead to 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. Avoid continuous operation at a steady speed.

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. Operating at maximum

2,000 ∼ 3,000 rpm should be limited to 50% of the 45 minutes.

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. Operating at maximum

4,000 ∼ 5,000 rpm should be limited to 50% of the 60 minutes.

30-second 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.

39

10/04/13 15:11:47 31ZX1600_041

OPERATION

FUEL PRIMING

UP

OUTLET END

(outboard motor side)

PRIMING BULB

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.

INLET END

(tank side)

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 touch the priming bulb with the engine running or when tilting up the outboard motor. The vapor separator could overflow.

40

10/04/13 15:11:56 31ZX1600_042

STARTING THE ENGINE

Control

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

. p. 41

Panel-Mount Type

Top-Mount Type

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

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

. p. 44

. p. 46

Side-Mount Type

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

1.

Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or

OPERATION

to the operator’s PFD (Personal

Flotation Device).

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

The emergency stop switch clip and emergency stop switch 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 emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine.

Before leaving the dock, check the operation of the emergency stop switch.

CONTROL

LEVER

N (neutral)

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.

41

10/04/13 15:12:04 31ZX1600_043

OPERATION

LOWEST

POSITION

OFF

ON

START

IGNITION SWITCH KEY

FAST IDLE LEVER

3.

Leave the fast idle lever in the

OFF (fully lowered) position.

The 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

ON position; the buzzer will sound twice.

5.


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.

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.

42

10/04/13 15:12:16 31ZX1600_044

MAXIMUM FAST IDLE

FAST IDLE

RANGE

FAST IDLE LEVER

6.

Before getting underway, allow the engine to warm-up sufficiently to ensure good performance.

Above 41°F (5°C), warm-up the engine for at least 3 minutes.

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

The cooling system may f reeze in areas where the temperature reaches 32°F (0°C) or below.

Cruising at high speed without warming the engine up may cause engine damage.

OPERATION

During the warm-up period, check

the oil pressure indicator (p.

34 ), overheat indicator (p.

34 ), and

cooling system indicator (p.

35 ).

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

TAKING CARE OF


p.

98 − 101 .

on

7.

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.

43

10/04/13 15:12:24 31ZX1600_045

OPERATION

Panel-Mount Type

EMERGENCY STOP

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

1.

Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD (Personal

Flotation Device).





CONTROL

LEVER

N (neutral)

2.


(neutral) position.



44

10/04/13 15:12:33 31ZX1600_046

OFF

ON

START

IGNITION

SWITCH KEY

3.



4.




OPERATION


N (neutral)



CONTROL

LEVER


5.




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

45

10/04/13 15:12:40 31ZX1600_047

OPERATION







34 ), and


35 ).


TAKING CARE OF


p.

98 − 101

.

on

6.

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

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

1.

Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD (Personal

Flotation Device).

46

10/04/13 15:12:49 31ZX1600_048

OPERATION





CONTROL

LEVER

N (neutral)

2.


(neutral) position.



OFF

ON

IGNITION

SWITCH KEY

START

3.



4.




47

10/04/13 15:12:57 31ZX1600_049

OPERATION


N (neutral)

48



CONTROL

LEVER


5.




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




10/04/13 15:13:07 31ZX1600_050




34 ), and


35 ).


TAKING CARE OF


p.

98 − 101 .

on

6.

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.

OPERATION

STOPPING THE ENGINE

Emergency Engine Stopping

Side-Mount Type

EMERGENCY STOP

SWITCH

EMERGENCY

STOP SWITCH

LANYARD

PULL

EMERGENCY STOP

SWITCH CLIP

Panel-Mount/Top-Mount Types

EMERGENCY

STOP SWITCH

CONTROL PANEL

EMERGENCY

STOP SWITCH

LANYARD

PULL

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

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



OFF position after verifying the emergency stop switch operation.

EMERGENCY STOP SWITCH CLIP

49

10/04/13 15:13:19 31ZX1600_051

OPERATION

Normal Engine Stopping


N (neutral)

CONTROL

LEVER

Panel-Mount Type

N (neutral)

CONTROL

LEVER

50

Top-Mount Type

N (neutral)


OFF

CONTROL

LEVER

IGNITION

SWITCH KEY

1.

Move the control lever(s) to the N

(neutral) position.

After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine.


O F F

2.


OFF position to stop the engine.

In the event that the engine does not stop when the ignition switch key is turned to OFF, press the emergency stop switch until the engine stops.

3.

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

IGNITION

SWITCH KEY

10/04/13 15:13:28 31ZX1600_052

GEARSHIFT AND

THROTTLE OPERATION


CONTROL LEVER

N (neutral)

NEUTRAL

RELEASE

LEVER

OPERATION


N (neutral)

F (forward)

CONTROL

LEVER

R (reverse)

NEUTRAL

RELEASE

LEVER

To shift gears, move the control lever to select the F (forward), N (neutral), or R (reverse) gear.

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.


N (neutral)

F (forward)

R (reverse)

F (forward)

R (reverse)

CONTROL

LEVER

51

10/04/13 15:13:36 31ZX1600_053

OPERATION

Side-Mount Type Top-Mount Type

TO INCREASE

FRICTION

TO INCREASE

FRICTION

TO DECREASE

FRICTION

CONTROL LEVER



CONTROL LEVER


TO INCREASE

FRICTION

TO DECREASE

FRICTION

CONTROL LEVER


Adjust the control lever 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.

52

TO DECREASE

FRICTION

10/04/13 15:13:46 31ZX1600_054

OPERATION

CRUISING

Engine Speed

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

throttle friction control (p.

52 ) 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 a rev 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 rev limiter.

If engine speed becomes unstable at high speed due to activation of the rev 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 underway 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.

31 ) for an

indication of whether the outboard 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 surface.

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.

53

10/04/13 15:13:57 31ZX1600_055

OPERATION




(single type)


OUTBOARD

MOTOR TRIMMED

TOO LOW

OUTBOARD

MOTOR TRIMMED

TOO HIGH

OUTBOARD MOTOR TRIMMED

CORRECTLY



(dual type)


(LEFT) (RIGHT)

BOW TOO LOW DUE TO

1.

2.

LOAD IN THE FRONT


TOO LOW

BOW TOO HIGH DUE TO

1.

2.

LOAD IN THE REAR


TOO HIGH

54

10/04/13 15:14:05 31ZX1600_056

Trolling Speed Control


SWITCH PANEL


OPERATION

DN: Reduce engine speed

UP: Increase engine speed

The engine must be fully warmed up before you can activate the Trolling

Speed Control.

Place the outboard motor in-gear with the throttle control in the fully closed (idle) position. Press and hold the UP or DN side of the TRL control switch to activate the Trolling

Speed Control. The buzzer will make one long sound indicating activation.

The initial trolling speed is set at 650

RPM.

The engine speed can be adjusted in

50 RPM increments by pressing the

UP or DN side of the TRL control switch. A short sound of the buzzer occurs each time the engine speed is adjusted.

In Trolling Speed Control mode, the engine speed can be adjusted between 650 and 900 RPM.

Continuing to press the switch when at either of these limits will result in two short sounds from the buzzer.

The throttle control will operate when in the Trolling Speed Control mode, but once the speed reaches

3,000 RPM, the Trolling Speed

Control is deactivated. If 3,000 RPM is not reached and the throttle is closed, the engine speed will decrease to the Trolling Speed

Control setting.

55

10/04/13 15:14:14 31ZX1600_057

OPERATION

TRIM TAB

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.

TRIM TAB

BOLT

SHALLOW WATER

OPERATION

When operating in shallow water, use

the power trim/tilt switch (p.

54 ) to

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

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

indicator (p.

35 ) to be sure the

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

68°

12°

0°

TILT ANGLE

16°

0°

−

4°

(VERTICAL LINE)

TRIM ANGLE

(when transom angle is 12°)

TRIM TAB

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

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

Refer to

on p.

64 .

TRIM TAB ADJUSTMENT

56

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

Limited Warranty

(p.

Distributor’s

113 ).

10/04/13 15:14:21 31ZX1600_058

OPERATION

MOORING, BEACHING,

LAUNCHING

Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine.

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 up as far as it will go.

Move the tilt lock lever to the LOCK position, and then gently lower the outboard motor until the lever contacts the stern bracket. Use the power tilt switch to fully shorten the trim rods.

TRIM RODS

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

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.

POWER TILT SWITCH

TILT LOCK LEVER

(Lock position)

F R E E

L O C K

STERN BRACKET

57

10/04/13 15:14:26 31ZX1600_059

OPERATION

MANUAL RELIEF VALVE

POWER

(To fix)

MANUAL

(To release)

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 outboard motor can also be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down 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 engine.

58

10/04/13 15:14:33 31ZX1600_060

THE IMPORTANCE OF

MAINTENANCE

Proper 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, Honda

Genuine 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.

59

10/04/13 15:14:42 31ZX1600_061


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.

Do not start or run the engine in a confined or partly enclosed area.

−

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.

60

10/04/13 15:14:49 31ZX1600_062

TOOL KIT and OWNER’S MANUAL

14

×

17 mm WRENCH 19 mm EYE WRENCH


SPARE EMERGENCY STOP

SWITCH CLIP


10

×

12 mm WRENCH SPARK PLUG WRENCH

OWNER’S MANUAL

8 mm WRENCH

16

×

17 mm BOX WRENCH

OIL CHECK

SCREWDRIVER

FLAT SCREWDRIVER

PLIERS

PHILLIPS

SCREWDRIVER

6 mm HEX. WRENCH

TOOL BAG

SCREWDRIVER HANDLE

The tool kit can be used for simple maintenance procedures and emergency repairs. Keep these items on the boat so that 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.

61

10/04/13 15:15:01 31ZX1600_063


MAINTENANCE SCHEDULE

Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim for warranty coverage will not be denied simply because the maintenance schedule for your outboard motor was not followed. However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance, would not be covered under the

Distributor’s Limited Warranty

.

REGULAR SERVICE PERIOD (3)

Perform at every indicated month or operating

First month

Every

6 months

Every year

Every

2 years Refer to hour interval, whichever comes first.

Each use After use or

20 hrs.

or

100 hrs.

or

200 hrs.

or

400 hrs.

page

ITEM

Engine oil Check level

Change

○

○ ○

66

Engine oil filter

Gear case oil

ACG belt

Throttle linkage

Idle speed

Replace

Change

Check-adjust

Check-adjust

Check-adjust

○

(2)

○

○

(2)

(2)

○

(2)

○

○

(2)

(2)

○

(2)

○ (2)

68

Valve clearance

Spark plug

(Standard plug)

Propeller and cotter pin

Anode metal

Anode metal

Check-adjust

Check-adjust/Replace

Check

Check Outside engine

Check Inside engine

○

○

○

○

(2)

72

−

74

83

82

○ (2) (6)

Lubrication

(3)

(6)

Grease

○

(1)

○

(1)

70

−

71

Water separator

(1)

Check

Lubricate more frequently when used in salt water.

(2)

○

80

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 there is 1/3 or more consumption, please exchange.

62

10/04/13 15:15:14 31ZX1600_064


REGULAR SERVICE PERIOD (3)

Perform at every indicated month or operating

First month

Every

6 months

Every year

Every

2 years Refer to hour interval, whichever comes first.

Each use After use or

20 hrs.

or

100 hrs.

or

200 hrs.

or

400 hrs.

page

ITEM

Fuel filter

(Low pressure side)

Fuel filter

(High pressure side)

Thermostat

Fuel line

Check

Replace

Replace

Check

Check

Replace

○

○

Every 2 years (If necessary) (2)

○ (2)

○

○

(2)

77 − 79

38

Battery and cable connection

Bolts and nuts

Crankcase breather tube

Cooling water passages

Water pump

Check level-tightness

Check-tightness

Check

Clean

Check

○

○ (4)

○

(2)

○

(2)

○ (2)

38

○ (2)

Emergency stop switch

Engine oil leak

Each operation part

Engine condition (5)

Power Trim/Tilt

Spark plug

Check

Check

Check

Check

Check

Check

○

○

○

○

○ (2)

38

(Optional iridium plug)

(1)

(2)

(3)

(4)

(5)

Clean

○

○

(2)

75

Replace

Lubricate more frequently when used in salt water.

○

75

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.

Upon starting, check for unusual engine sounds and cooling water flowing freely from the check hole.

63

10/04/13 15:15:24 31ZX1600_065


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

TRIM TAB BOLT

LEFT

TRIM TAB

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

RIGHT

RIGHT

TRIM TAB 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.

64

10/04/13 15:15:34 31ZX1600_066



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 up or down 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.



ENGINE COVER REMOVAL

AND INSTALLATION

ENGINE COVER

UNLOCK


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

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.

The cover should be tight at the midcase point. If the cover is loose or difficult to secure, an adjustment may be necessary. Please see the shop manual or your Honda Marine dealer for adjustment.

65

10/04/13 15:15:46 31ZX1600_067


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.

65 ).

2.

Remove the dipstick and wipe it clean.

OIL FILLER CAP

Engine Oil Change

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

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

1.


cover (p.

65 ).

DRAIN BOLT COVER

UPPER

LIMIT

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.

69

.

3.

OIL LEVEL DIPSTICK

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

LOWER

LIMIT

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.

LEVER

2.

Push the drain bolt cover lever and remove the cover while pulling the cover backward at an angle.

66

10/04/13 15:15:54 31ZX1600_068



GUIDE

SEALING WASHER

D R A I N

B O L T

DRAIN

BOLT

COVER

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 throw it in the trash, pour it on the ground or down a drain.


GUIDE


GUIDE

3.

Set the drain bolt cover under the guide.

4.

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

5.

Allow the used oil to drain completely. Use a new sealing washer, and then reinstall the engine oil drain bolt and washer.

Tighten the drain bolt securely.

UNDER COVER

PUSH

LEVER

LOCKING LUG

PROJECTION

67

10/04/13 15:16:04 31ZX1600_069


6.

Install the oil drain bolt cover.

Push the lever of the oil drain bolt cover in the direction pointed by the arrow mark of ‘‘LOCK’’, and install the oil drain bolt cover so that the locking lug securely sets on the projection of the under cover.

7.

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

limit mark on the dipstick (p.

66 )

with the recommended oil.

Engine oil refill capacity:

Without oil filter change:

6.9 US qt (6.5 L)

With oil filter change:

7.1 US qt (6.7 L)

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 then reinstall the drain bolt and sealing washer. Reinstall the drain bolt cover (see Engine Oil Change

on p.

66 ).

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 thoroughly drain the filter into the used oil container.

FILTER WRENCH, 65 mm

OIL FILTER

OIL DRAIN GUIDE

RUBBER SEAL

68

10/04/13 15:16:15 31ZX1600_070

4.

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

Use only a Honda Genuine 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 3/4 turn.

OIL FILTER TIGHTENING

TORQUE:

9 lbf·ft (12 N·m , 1.2 kgf·m)

6.

Return the outboard motor to the vertical position, and fill the crankcase with the specified amount of the recommended oil.


7.

Start the engine and check for leaks (be sure the water level is at least 2 inches (5 cm) above the antiventilation plate).

If you are changing the oil filter while the outboard motor is out of the water, use commercially available ear muffs and water hose to supply water.

Engine Oil Recommendations

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

4-stroke detergent oil.

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

8.

Stop the engine, and check the oil

level as described on page 66 . If

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

AMBIENT TEMPERATURE

Honda 10W-30 FC-W

TM outboard motor oil is recommended for general use.

If Honda 10W-30 FC-W oil is not available, Honda recommends that you use API service category SG, SH or SJ oil. The SAE oil viscosity and service category are in the API label on the oil container.

69

10/04/13 15:16:21 31ZX1600_071


Lubrication Points

Apply Honda Marine waterproof grease to the parts shown below:

THROTTLE LINK/

PIVOT/PLATE

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

ENGINE COVER BRACKET

THROTTLE ROD/LINK

TILT BRACKET

TILT SHAFT

PTT THRUST RECEIVER

PROPELLER SHAFT SWIVEL CASE

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

70

10/04/13 15:16:26 31ZX1600_072


ENGINE COVER

LOCK CABLE

(LEFT SIDE)

THROTTLE ARM/

SHIFT ARM/PIVOT

PLATE/NEUTRAL

SWITCH/CLICK

ARM ROLLER

ENGINE COVER

CABLE (FRONT)

ENGINE COVER LOCK

LEVER/OPEN SHAFT

COVER LOCK BOLTS

TILT LOCK LEVER

ENGINE COVER

LOCK CABLE

(RIGHT SIDE)

SWIVEL SHAFT

TILT SHAFT THREAD

LOWER CYLINDER

BUSH/COLLAR

UPPER CYLINDER PIN/

BUSH

71

10/04/13 15:16:37 31ZX1600_073


Spark Plug Service

〈

Standard Spark Plug

〉

RECOMMENDED SPARK PLUGS:

ZFR6K-11 (NGK)

KJ20DR-M11 (DENSO)

UNDER COVER

GROMMET

UNDER

COVER

Incorrect spark plugs can cause engine damage.

See page 75

for instructions of handling the Iridium spark plugs

(optional parts).

1.

Disconnect the battery negative

( − ) terminal.

2.


cover (p.

65 ).

CLIP

CLIP (2)

3.

Remove the two clips from the upper part of the under cover grommet.

To remove the clips, raise the inner part of each clip with a screwdriver, then pull out the clips.

Do not try to remove the clip with f orce without raising the inner part of the clip. Otherwise, it can damage the clip and/or under cover.

4.

Fold down the upper part of the under cover grommet without removing it from the idle port.

CLIP

IDLE PORT

UNDER COVER GROMMET

72

10/04/13 15:16:45 31ZX1600_074

SPARK PLUG COVER


IGNITION COIL

8.

Remove the ignition coil by pulling it up slightly.

BOLT

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

BOLTS

5.

Remove the two bolts with the 6 mm hex wrench, and remove the spark plug cover.

WIRE CONNECTOR

6.

Use a 6 mm hex. wrench to remove the bolt holding the ignition coil. Move the ignition coil to a position that allows removal of the wire connector easily.

7.

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.

SPARK PLUG

WRENCH

19 mm EYE

WRENCH

9.

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

73

10/04/13 15:16:59 31ZX1600_075


SIDE ELECTRODE

0.039

(1.0

−

−

0.043 in

1.1 mm)

SEALING

WASHER

INSULATOR

10.

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

11.

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

Correct the gap, if necessary, by carefully bending the side electrode.

The gap should be:

0.039

− 0.043 in

(1.0

− 1.1 mm)

12.

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

15.

Install the ignition coil. Reinstall the bolt.

13.

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

16.

Repeat this procedure for the other three spark plugs.

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.

17.

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

CLIP

UNDER

COVER

GROMMET

UNDER

COVER

Loose spark plugs can overheat and damage the engine.

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

14.

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

Clip installation:

Press the under cover grommet and under cover and be sure that they adhere closely to each other.

Insert the clips with the inner part raised off, then push in the inner part securely until they click.

74

10/04/13 15:17:08 31ZX1600_076

〈

Optional Parts : Iridium

Spark Plug

〉

RECOMMENDED SPARK PLUGS:

IZFR6K11 (NGK)

SKJ20DR-M11 (DENSO)

Incorrect spark plugs can cause engine damage.

Installation and removal procedure of the Iridium spark plugs are the same as the standard spark plugs.

These spark plugs have an iridium coated center electrode.

Be sure to observe the following when servicing iridium 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.’’

The gap should be 0.039

−

0.051

inches (1.0

− 1.3 mm).

Do not adjust the spark plug gap.

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

REFUELING

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

75

10/04/13 15:17:17 31ZX1600_077







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.


Fuel can damage paint and plastic.

Be caref ul not to spill f uel when f illing your f uel tank. Damage caused by spilled f uel is not covered under warranty.

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.

You may use unleaded gasoline containing no more than 10% ethanol

(E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors.

Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system.

76

10/04/13 15:17:25 31ZX1600_078


Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty.

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the

STORAGE chapter (p.

85 ) for

additional information regarding fuel deterioration.

Fuel Filter Inspection and

Replacement

The fuel filter (inside the strainer cup) is located below the intake manifold.

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






77

10/04/13 15:17:32 31ZX1600_079


ENGINE COVER

STRAINER

ASSEMBLY

FUEL HOSES

UNLOCK


1.

Remove the engine cover (p.

65 ).

FUEL FILTER

(inside strainer cup)

2.

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

SUSPENSION STRAP

3.

Remove the strainer assembly. If it is difficult to remove the strainer assembly by yourself, consult an authorized Honda Marine dealer.

Remove the suspension strap from the fuel filter bracket, and then remove the strap from the fuel filter assembly.

4.

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

78

10/04/13 15:17:42 31ZX1600_080


STRAINER BODY

FUEL FILTER

STRAINER CUP

SCREW (3)

5.

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

6.

Thoroughly clean the strainer cup, and replace the fuel filter.

7.

Reassemble the strainer body and the cup.

STRAINER TIGHTENING

TORQUE:

2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

FUEL STRAINER ASSEMBLY

STRAINER

BRACKET

10.

Prime the engine using the priming

bulb (refer to page 40 ). 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.

SUSPENSION

STRAP

ALIGNMENT

POSITION

STRAINER CUP

8.

Align the center of suspension strap with the screw position and install the fuel strainer assembly.

9.

Reinstall the strainer assembly in the original position.

79

10/04/13 15:17:52 31ZX1600_081


Water Separator Inspection and

Service

INTAKE MANIFOLD






WATER SEPARATOR

The water separator is located below the intake manifold. 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.

1.


65 ).

2.

Remove the separator assembly. If it is difficult to remove the separator assembly by yourself, consult an authorized Honda

Marine dealer.

SEPARATOR

ASSEMBLY

FUEL TUBES

SUSPENSION STRAP

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

During removal of the separator assembly, take care not to damage the wire harness with the separator bracket.

3.

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

80

10/04/13 15:18:02 31ZX1600_082


CUP

O-RING

BOWL SUSPENSION STRAP

4.

Remove the three screws and separate the bowl from the body.

5.

Thoroughly clean the bowl.

6.

Reassemble the water separator bowl, O-ring, and cup.

TIGHTENING TORQUE:

2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

WATER SEPARATOR BRACKET

WATER SEPARATOR

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.

SUSPENSION

STRAP

ALIGNMENT

POSITION

BOWL

7.

Align the center of suspension strap with the screw position and install the water separator assembly.

8.

Reinstall the water separator in the reverse order of removal.

81

10/04/13 15:18:10 31ZX1600_083


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

(each side)

ANODE

(stern bracket)

The anodes are located on each side of the gear case and on the stern bracket. 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 one third their original size, or if they are crumbling.

Propeller Replacement

Before replacing the propeller, remove the emergency stop switch clip from the emergency 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, and then remove the propeller and thrust washer.

2.

Inspect the propeller shaft for any fishing line or debris.

82

10/04/13 15:18:21 31ZX1600_084

Installation

1.

Apply marine grade grease to the propeller shaft.

2.

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

3.

Install the propeller.

4.

Install the washer with as shown.

5.

Lightly tighten the castle nut by hand or wrench until the propeller has no free play.

6.

Tighten the castle nut using a torque wrench.

CASTLE NUT TIGHTENING

TORQUE:

0.7 lbf·ft (1 N·m, 0.1 kgf·m)

7.

Then, using a torque wrench, tighten the castle nut until the first available groove in the castle nut aligns with the cotter pin hole. Do not tighten past the first alignment of the castle nut groove and the


cotter pin hole.

TIGHTENING TORQUE LIMIT:

33 lbf·ft (44 N·m , 4.5 kgf·m)

Do not tighten the castle nut above the TIGHTENING TORQUE LIMIT, or the propeller and shaf t may be damaged.

8.

Be sure to replace the cotter pin with a new one.

Use a Honda Genuine stainless steel cotter pin or equivalent cotter pin and bend the pin ends as shown.

Note that these wrenches are not included with the tool set that comes with the outboard motor. Contact your authorized Honda Marine dealer for additional tool information.

MARINE GREASE

THRUST WASHER

PROPELLER

WASHER

COTTER PIN

(stainless)

CASTLE NUT

83

10/04/13 15:18:31 31ZX1600_085

STORAGE

STORAGE PREPARATION

Proper storage preparation is essential for keeping your outboard motor trouble-free 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.

such as the AC generator, HO2S sensor, or the AC generator belt. If water or corrosion inhibitor penetrates these components, they may be damaged. Bef ore applying a corrosion inhibitor, cover the AC generator, belt and HO2S sensor with a protective material to prevent damage.

Cleaning

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

Flushing With a Garden Hose

(commercially available)

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

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover,

84

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

1.

Tilt down the outboard motor.

2.

Clean and wash the outside of the outboard motor with fresh water.

FLUSH PORT

CONNECTOR

3.

Disconnect the flush port connector.

10/04/13 15:18:39 31ZX1600_086

FLUSH PORT

CONNECTOR

GARDEN HOSE

GARDEN HOSE JOINT

(Commercially available)

4.

Screw the flush port connector onto the garden hose.

STORAGE

EXHAUST PORT

5.

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

6.

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

7.

Tilt up the outboard motor and move the tilt lock lever to the

LOCK position.

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.

85

10/04/13 15:18:48 31ZX1600_087

STORAGE

You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining all the fuel from the fuel tank and vapor separator.

The

(p.

Distributor’s Limited Warranty

113 ) does not cover fuel system

damage or engine performance problems resulting from neglected storage preparation.

Adding a Fuel Stabilizer

When adding a fuel stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep an additional container of gasoline for refueling, be sure that it contains only fresh gasoline.

1.

Drain the vapor separator before adding fuel stabilizer.

2.

Add fuel stabilizer following the manufacturer’s instructions.

3.

After adding a fuel stabilizer, run the engine in water for 10 minutes to be sure that the treated gasoline has replaced the untreated gasoline in the vapor separator.

4.

Turn the engine OFF.

Draining the Fuel System

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

FRONT BRACKET CLAMP

DRAIN SCREW

VAPOR SEPARATOR

DRAIN HOSE

(Draining the fuel becomes easier when the front end of the drain hose is as low as possible)

86

10/04/13 15:19:02 31ZX1600_088

1.

Unhook the drain hose from the front bracket clamp.

2.

Set the end of the hose toward the outside of the engine undercase.

Place an approved gasoline container below the fuel drain outlet, and use a funnel to avoid spilling fuel.

3.

Loosen the vapor separator drain screw.






STORAGE

4.

Tilt the outboard motor up all the way. Leave the outboard motor tilted up until the gasoline stops flowing.

5.

After thoroughly draining, tighten the drain screw securely and return the outboard motor to the vertical position.

6.

Clamp the drain hose on the front bracket clamp.

7.

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.

66 − 69 ).

2.

Remove the spark plugs (p.

72 ),

and remove the emergency stop switch clip from the emergency stop switch.

3.

Pour 1 − 2 teaspoons (5 − 10 cm )

(p.

102 ) 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.

74 ).

87

10/04/13 15:19:10 31ZX1600_089

STORAGE

HOISTING THE OUTBOARD

MOTOR

ENGINE COVER

LIFTING

EYES

HOIST

HOOKS

UNLOCK


1.


65 ).

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.

88

10/04/13 15:19:16 31ZX1600_090

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 commercially available stand.

PROTECTOR

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

the vapor separator (p.

86 ), and

drain the engine oil (p.

66 ), before

removing the outboard motor from the boat.

Rest the outboard motor on a cushion of protective material.

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

STORAGE

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.

89

10/04/13 15:19:22 31ZX1600_091

TRANSPORTING

WITH OUTBOARD MOTOR

INSTALLED ON BOAT

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

Use an outboard motor support bar to prevent the outboard motor from moving while trailering the boat.

Refer to the manufacturer’s instructions for using an outboard motor support bar.

WITH OUTBOARD MOTOR

REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position

shown on p.

89 .

OUTBOARD MOTOR SUPPORT BAR

(commercially available)

90

10/04/13 15:19:32 31ZX1600_092

TAKING CARE OF UNEXPECTED PROBLEMS

1.

ELECTRIC STARTER WILL

NOT OPERATE

Check battery.

2.

Check fuses.

3.

Use starting procedure (p.

41 ,

,

); if engine still will not

start, then take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual.

Possible Cause Correction

Battery connections loose or corroded.

Battery discharged.

Fuse(s) blown.

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

Clean and tighten battery connections.

Recharge battery.

Replace fuse(s) (p.

96 ).

Replace or repair faulty components as necessary.

91

10/04/13 15:19:45 31ZX1600_093


ENGINE WILL NOT START

1.

Check emergency stop switch clip.

2.

Check control positions.

3.

Check fuel.

Possible Cause

Clip not inserted in emergency stop switch.

Control lever not in neutral position.

Fast idle lever raised (side-mount type).

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

Insert clip in emergency stop switch.

Shift to neutral.

Leave fast idle lever OFF (p.

42 ).

Refuel (p.

75 ).

Squeeze priming bulb (p.

40 ).

Replace fuel filters (p.

77 ).

Drain fuel tank and vapor

separator (p.

86 ). Refill with

fresh gasoline (p.

75 ).

92

10/04/13 15:19:55 31ZX1600_094


ENGINE WILL NOT START

(continued)

4.

Check water separator.

Possible Cause

5.

Remove and inspect spark plugs.

6.

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

Water separator full of water accumulation.

Spark plugs faulty, fouled, or improperly gapped.

Spark plugs wet with fuel (flooded engine).

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

Correction

Clean water separator (p.

80 ).

Gap (non-iridium type) or replace

spark plugs (p.

72 ).

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


93

10/04/13 15:20:05 31ZX1600_095


HARD STARTING OR STALLS

AFTER STARTING

1.

Check control positions.

2.

Check fuel.

3.

Check water separator.

Possible Cause Correction

Fast idle lever raised (side-mount type).

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

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

Water separator full of water accumulation.

Leave fast idle lever OFF (p.

42 ).

Squeeze priming bulb (p.

40 ).

Replace fuel filters (p.

77 ).

Drain fuel tank and vapor

separator (p.

86 ). Refill with

fresh gasoline (p.

75 ).

Clean water separator (p.

80 ).

94

10/04/13 15:20:16 31ZX1600_096


HARD STARTING OR STALLS

AFTER STARTING

(continued)

4.

Remove and inspect spark plugs.

Possible Cause

5.


Spark plugs faulty, fouled, or improperly gapped.

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

Correction

Gap (non-iridium type) or replace

spark plugs (p.

72 ).


ENGINE OVERHEATS

1.

Check water intake screens.

2.


Possible Cause

Water intake screens clogged.

Faulty thermostat or water pump.

Correction

Clean water intake screens.


95

10/04/13 15:20:27 31ZX1600_097


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 100A ACG fuse protects the alternator circuit. If the ACG fuse blows, the engine will not charge the

battery. Refer to p.

98 .

Fuse Replacement

Disconnect the battery cable at the battery negative (

−

) terminal bef ore replacing the f use.

Failure to do so may cause a short circuit.

Main Fuse

1.

Stop the engine and disconnect the battery cable.

2.

Remove the engine cover.

SPARE FUSES

(10A, 15A, 30A)

3.

Remove the junction box lid.

FUSE PULLER

RELAYS

(Do not remove the relays)

FUSE

HOLDER

FUSES (10A, 15A, 30A)

4 5 °

JUNCTION

BOX LID

96

10/04/13 15:20:34 31ZX1600_098

FUSE PULLER

BLOWN FUSE


4.

Use the fuse puller from the fuse holder 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 junction box lid.

MAIN FUSE RATINGS:

10 A, 15 A, 30 A

5.

Reinstall the junction box lid, and the engine cover.

6.

Reconnect the battery.

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.

97

10/04/13 15:20:47 31ZX1600_099


ACG Fuse

5.

Install a new fuse with the ‘‘100A.’’

ACG FUSE:

100 A

OIL PRESSURE INDICATOR

GOES OFF AND ENGINE

SPEED IS LIMITED

6.

Reinstall the junction box lid, and the engine cover.


OIL PRESSURE

INDICATOR

7.

Reconnect the battery.

A spare fuse is located in the fuse holder.

(GREEN)

SPARE FUSE (100A) FUSE (100A)

FUSE HOLDER

1.

Stop the engine and disconnect the battery cable.

2.

Remove the engine cover.

3.

Remove the junction box lid (see

page 96 ).

4.

Remove the old fuse by removing two 5 mm screws.

BUZZER


OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

98

10/04/13 15:20:58 31ZX1600_100



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.

66 ), 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.

OVERHEAT INDICATOR

COMES ON AND ENGINE

SPEED IS LIMITED


OVERHEAT

INDICATOR

(RED)

BUZZER


OVERHEAT

INDICATOR

(RED)

BUZZER

99

10/04/13 15:21:07 31ZX1600_101



Normal

Abnormal

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.

100

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

COOLING SYSTEM INDICATOR

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.

If there is no water flowing from the cooling system indicator, stop the engine, and tilt the outboard motor to inspect the water intake screens. If restricted, 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.

10/04/13 15:21:18 31ZX1600_102

WATER SEPARATOR

BUZZER SOUNDS


WATER SEPARATOR

INDICATOR

Digital Speedometer

Normal

Abnormal

WATER SEPARATOR

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

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

on page 80 , or consult with an

authorized Honda Marine dealer.

When the water separator indicator blinks:

Check the water separator for water contamination. If water is present, stop the engine, and clean the water separator following the instructions on page 80 , or consult with an authorized Honda Marine dealer.

SUBMERGED OUTBOARD

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 dealership nearby, take the outboard 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.

86

.

101

10/04/13 15:21:27 31ZX1600_103


3.

Change the engine oil and oil filter

as described on p.

66

−

69 . 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.

72 ).

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

5.

Pour a teaspoon (p.

87 ) 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).

If you are changing the oil filter while the outboard motor is out of the water, use commercially available ear muffs and water hose to supply water.

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 2 inches (5 cm) 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.

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

102

10/04/13 15:21:34 31ZX1600_104

TECHNICAL AND CONSUMER INFORMATION

TECHNICAL INFORMATION

Serial Number Locations

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

warranty inquiries (p.

110 ).

PRODUCT

IDENTIFICATION

NUMBER

RIGHT 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 engine.

Engine serial number:

Date of purchase:

103

10/04/13 15:21:42 31ZX1600_105


Battery

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

Minimum Requirements

12V − 64Ah/5HR (80Ah/20HR)

(CCA622)

Be caref ul to avoid connecting the battery in reverse polarity, as this will damage the battery-charging system in the outboard motor.

Do not disconnect the battery cables while the engine is running.

Disconnecting the cables while the engine is running will damage the outboard motor’s electrical system.

Battery cable extension: Extending the original battery cable will cause the battery voltage to drop due to the increased length of the cable and number of connections.

This voltage drop may cause the buzzer to sound momentarily when

104

engaging the starter motor and may prevent the engine f rom starting. If the engine starts and the buzzer sounds momentarily, there may be barely suf f icient voltage reaching the engine.

WARNING:

Battery posts, terminals, and related accessories contain lead and lead compounds.

Wash your hands after handling.

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 appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

10/04/13 15:21:50 31ZX1600_106

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.

105

10/04/13 15:21:59 31ZX1600_107


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 Honda Genuine 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.

62 and 63 ). Remember that this

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

106

10/04/13 15:22:09 31ZX1600_108

Star Label

US, Puerto Rico, and US Virgin

Islands

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.

107

10/04/13 15:22:17 31ZX1600_109


One Star

Low

Emission

Two Stars

Very 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.

Three Stars

Ultra Low

Emission

Four Stars

Super Ultra

Low Emission

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

108

10/10/12 10:16:33 31ZX1600_110


Specifications

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

[weight] ＊

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

Lubrication system

Specified oil

LA

BF115D

BBHJ

LC XA

33.3 in (845 mm)

XC XCA

22.8 in (580 mm)

65.6 in (1,665 mm) 70.5 in (1,790 mm)

20.0 in (508 mm) 25.0 in (635 mm)

478 lbs 485 lbs

(217 kg) (220 kg)

85.8 kW (115 HP)

4,500 − 6,000 rpm

492 lbs

(223 kg)

4 stroke DOHC in-line 4-cylinder

143.6 cu-in (2,354 cm )

0.039

− 0.043 in (1.0

− 1.1 mm)

Electric starter

Fully transistorized, battery ignition

Trochoid pump pressure lubrication

Oil capacity

Engine: API standard (SG, SH, SJ) SAE 10W-30

Gear case: API standard (GL-4) SAE 90 outboard motor gear oil

Engine: 6.9 US qt (6.5 L) without oil filter change

7.1 US qt (6.7 L) with oil filter change

Gear case: 1.04 US qt (0.98 L)

＊

Without battery cable, with propeller

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Tilt up angle


Trim angle


Tune Up

Spark plug gap

Idle speed

Valve clearance

(cold)

Other specifications

ULTRA · LOW EMISSION

12V − 40A

Water cooling with thermostat

Water exhaust

KJ20DR-M11 (DENSO)

ZFR6K-11 (NGK)

Low pressure side:

High pressure side: mechanical type electrical type

Unleaded gasoline

(86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

Stageless (72°)

− 4° to 16°

0.039

− 0.043 in

(1.0

− 1.1 mm)

750 ± 50 rpm

See page 74

See shop manual

Intake: 0.23

± 0.02 mm

Exhaust: 0.30

± 0.02 mm

See shop manual

No other adjustment is needed

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

109

10/04/13 15:23:08 31ZX1600_111


CONSUMER INFORMATION

Honda Publications

(United States, Puerto Rico, and

U.S. Virgin Islands)

These publications will give you additional information for maintaining and repairing your outboard motor.

Shop Manual

This manual covers complete maintenance and overhaul procedures.

It is intended to be used by a skilled technician.

Available through your Honda

Marine dealer or through Helm Inc.

at

1 888-292-5395 or visit www.Honda-marine.com

and click on OWNERS’

RESOURCES.

Parts Catalog

This manual provides complete, illustrated parts lists.

The catalog is available through your

Honda Marine dealer.

110

Accessory Catalog

Your authorized Honda Marine dealer offers a wide selection of accessories (optional equipment, oils, and lubricants) to enhance your boating experience.

Visit www.honda-marine.com and click on PARTS & ACCESSORIES to see the entire catalog of accessories.

Customer Service Information

differences at the dealership level. If the service personnel are unable to assist you, please discuss your concerns with the dealer management such as the Service Manager or the dealership’s owner.

If you need to contact American

Honda regarding your experiences with your Honda product or with your dealer, please send your comments to the following address:

Contacting Honda

Your Owner’s Manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the Owner’s

Manual can be answered by your

Honda dealer. If your dealer doesn’t have an immediate answer, they should be able to get it for you.

If you have a difference of opinion with your dealer, please remember that each dealership is independently owned and operated. That’s why it’s important to work to resolve any

American Honda Motor Co., Inc.

Marine Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, GA 30005-8847

Telephone (770) 497

−

6400

M-F 8:30 am-7:00 pm (Eastern Time

Zone)

Honda Canada Inc.

Customer Relations Office

Visit www.honda.ca for contact information

Tel: 1-888-946-6329 (Toll free)

Fax: 1-877-939-0909 (Toll free)

10/04/13 15:23:19 31ZX1600_112

Please include the following information in your communication:

Your name, address and telephone number (complete with area code)

Model and complete serial number

Date of purchase

Name and location of selling dealer

Name and location of servicing dealer (if different)

A detailed description of your concerns


Warranty Coverage

Your new Honda is covered by the following warranties:

Distributor’s Limited Warranty

Emission Control System

Warranty

Please read the warranty statements contained in this manual. There are responsibilities, restrictions, and exclusions that apply to these warranties.

To obtain warranty service you must take your Honda outboard motor, together with proof of original retail purchase date, at your expense, to a

Honda engine dealer or distributor authorized to sell that product in the

United States, Puerto Rico, the U.S.

Virgin Islands or Canada.

It is important to realize that your warranty applies to defects in material or workmanship of your

Honda. Your warranty coverage does not apply to normal wear or deterioration associated with using your Honda outboard motor.

Your warranty coverage will not be voided if you choose to perform your own maintenance. However, you should have the proper tools and service information and be mechanically qualified. Failures that occur due to modifications, improper maintenance, or service are not covered.

111

10/04/13 15:23:23 31ZX1600_113


Warranty Service

Please remember that recommended maintenance interval servicing is not included in your warranty coverage.

Additionally, your warranty does not apply to the normal wear of items

(such as spark plug(s), water pump, etc.).

As the owner of a Honda product, your servicing dealer may ask you to authorize an inspection. If the problem is covered under warranty, your dealer will perform any warranty repairs for you at no cost.

However, you may be responsible for additional non-warranty charges.

If you have questions about warranty coverage or the nature of the repair, it is best to talk to the service manager of your Honda dealer.

Sometimes, in spite of the best intentions of all concerned, a misunderstanding may occur. If you aren’t satisfied with your dealer’s

112

handling of the situation, we suggest you discuss your problem with the appropriate member of the dealership’s management team. If the problem has already been reviewed with the appropriate manager of the

Service, Parts, or Sales department, contact the owner of the dealership or their designated representative.

10/04/13 15:23:34 31ZX1600_114


Warranty Statements

The American Honda Distributor’s Limited Warranty applies to outboards purchased in the United States, Puerto Rico, or the U.S. Virgin Islands. The Honda Canada Distributor’s Warranty applies to outboards purchased in Canada.

The product warranty is only valid in the country where the product was purchased.

United states, Puerto Rico and Virgin Islands

Distributor’s Limited Warranty

This warranty is limited to Honda Outboard Motors and related original equipment distributed by American Honda

Motor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.

Products Covered by Warranty:

All models purchased before July 1, 2008

(1) (2)

All Models purchased on or after July 1, 2008

(2)

Length of Warranty: (from date of original retail purchase)

NONCOMMERCIAL/ COMMERCIAL/RENTAL STATE/LOCAL/FEDERAL

NONRENTAL

36 months

60 months

12 months

12 months

GOVERNMENT

24 months

24 months

Related original equipment items:

BF2 through BF30 models: Portable fuel tank and original propeller.

The same duration as the outboard with which they were purchased.

(3)

All models: Primer bulb/fuel line assembly and tiller handle.

(1) Models purchased prior to July 1, 2008 (unless previously purchased with True-5 warranty from a participating dealer).

(2) 35, 65, & 105 Jet models: Jet pump assembly is a dealer installed option. Jet pump warranty is provided by Specialty Manufacturing Co. (Outboard Jets).

(3) Portable fuel tanks: 24 months or the same duration as the outboard they were purchased with, whichever is longer.

113

10/04/13 15:23:40 31ZX1600_115


To Qualify for This Warranty:

The Honda Outboard Motor must be purchased from

American Honda or a dealer authorized by American

Honda to sell Honda Outboard Motors in the United

States, Puerto Rico, or the U.S. Virgin Islands. This limited warranty applies to the first retail purchaser and each subsequent owner during the applicable warranty time period.

What American Honda Will Repair or Replace Under

Warranty:

American Honda will repair or replace, at its option, any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period. Warranty repairs and replacements will be made without charge for parts or labor. Anything replaced under warranty becomes the property of

American Honda Motor Company, Inc.

All parts replaced under warranty will be considered as part of the original product and any warranty on those parts will expire coincidentally with the original product warranty.

To Obtain Warranty Service:

You must, at your expense, take your Honda Outboard

Motor and proof of the original purchase date to any dealer who is authorized to service Honda Outboard

Motors in the United States, Puerto Rico, or the U.S.

Virgin Islands, during the dealer’s normal business hours.

If you are unable to obtain warranty service, or are dissatisfied with the warranty service you receive, take the following steps: First, contact the owner of the dealership involved; normally this should resolve the problem. However, if you should require further assistance, write or call the Honda Marine Customer

Relations. Please see

Contacting Honda

page 110 .

114

10/04/13 15:23:51 31ZX1600_116

Exclusions:

This warranty does not extend to the following:

Conditions caused by lack of routine maintenance or improper storage (as outlined in the Owner’s Manual)

Conditions caused by the use of propeller (s) that do not allow the outboard motor to run in its recommended full throttle rpm range

Operation inconsistent with the recommended operation/duty cycle (as outlined in the Owner’s

Manual)

Parts affected or damaged by an abuse, submersion and/or collision

Normal wear and tear

Fuel contamination and water entering engine through the fuel intake, air intake or exhaust system

Operation with fuels, oils, additives and lubricants which are not suitable for use in the product

Use in an application for which the outboard motor was not designed, such as racing or competitive use or any other misuse or neglect

Incorporation of unsuitable attachments or parts

The unauthorized alteration, improper installation and/ or rigging, or any causes other than defects in material or workmanship

Corrosion to steering system or electrical components, corrosion due to electrolysis, water born foreign chemicals, improper service or corrosion caused by damage or abuse


Reimbursement for towing charges, in and out of water charges, or technician travel time

Growth of marine organisms on outboard motor surfaces, external or internal

Any product that has ever been declared a total loss or sold for salvage by a financial institution or insurer, or

’’

Disclaimer of consequential damage and limitation of implied warranties:

American Honda disclaims any responsibility for loss of time or use of the outboard, revenue, or the equipment in which the outboard is installed, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written limited warranty.

Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

115

10/04/13 15:23:59 31ZX1600_117


Accessories and Replacement Parts

This warranty is limited to Honda Marine parts, accessories and apparel when distributed by American Honda Motor Co.,

Inc., 1919 Torrance Blvd., Torrance, California 90501-2746.

Products Covered by Warranty: Length of Warranty: (from date of original retail purchase)

Non Commercial Commercial/Rental Local/State/Federal

Government

Accessories other than noted below

12 months 3 months 3 months

Emission related accessories:


Portable fuel tanks, fuel line assemblies, and water/fuel separators

Replacement Parts


To Qualify for This Warranty:

1.

The accessories or replacement parts must be purchased from American Honda or a dealer, distributor, or distributor’s dealer authorized by

American Honda to sell those products in the United

2.

States, Puerto Rico, and the U.S. Virgin Islands. Parts and Accessories must be purchased for installation on original Honda equipment or engines to be eligible for warranty coverage. Installing parts and accessories on non-Honda products or engines voids this warranty.

You must be the first retail purchaser. This warranty is not transferable to subsequent owners.

What American Honda Will Repair or Replace Under

Warranty:

American Honda will repair or replace, at its option, any

116

marine product accessories or replacement parts that are proven to be defective in material or workmanship under normal use during the applicable warranty time period.

Anything replaced under warranty becomes the property of American Honda Motor Company, Inc. All parts replaced under warranty will be considered as part of the original product and any warranty on those parts will expire coincidentally with the original product warranty.

Accessories and replacement parts, installed by a dealer who is authorized by American Honda to sell them, will be repaired or replaced under warranty without charge for parts or labor. If installed by anyone else, accessories and replacement parts will be repaired or replaced under warranty without charge for parts, but any labor charges will be the responsibility of the purchaser.

10/04/13 15:24:04 31ZX1600_118


To Obtain Warranty Service:

You must, at your expense, take the Honda Outboard

Motor product accessory or replacement part or the outboard motor or boat on which the accessory or replacement part is installed, and proof of purchase to any Honda Marine authorized service facility or dealer in the United States, Puerto Rico, or the U.S. Virgin Islands, during normal business hours.

Exclusions:

This warranty does not extend to accessories or parts affected or damaged by collision, normal wear, use in an application for which the product was not designed or any other misuse, neglect, incorporation or use of unsuitable attachments or parts, unauthorized alteration, improper installation, or any causes other than defects in material or workmanship of the product.

Installing parts and accessories on non-Honda products or engines voids this warranty.

Disclaimer of consequential damage and limitation of implied warranties:

American Honda disclaims any responsibility for loss of time or use of the outboard motor, or the boat on which the product is installed, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written warranty. Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

117

10/04/13 15:24:11 31ZX1600_119


Emission Control System Warranty

Your new Honda outboard engine complies with both the

U.S. EPA and State of California emission regulations.

American Honda provides the same emission warranty coverage for outboard engines sold in all 50 states.

YOUR WARRANTY RIGHTS AND OBLIGATION

California

The California Air Resources Board and American

Honda Motor Co., Inc. are pleased to explain the emission control system warranty on your 2001 and later

Honda outboard engine. In California, new outboard engines must be designed, built, and equipped to meet

California’s stringent anti-smog emission standards in addition to the U.S. EPA emissions standards.

All States

In all areas of the United States your outboard engine must be designed, built, and equipped to meet the U.S.

EPA Emission Standard for spark ignited marine engines.

American Honda Motor Co., Inc. must warranty the emission control system on your outboard engine for the period of time listed below provided there has been no abuse, neglect, or improper maintenance of your outboard engine. Where a warranty condition exists,

American Honda Motor Co., Inc. will repair your

118

outboard engine at no cost to you including diagnosis, parts and labor.

Your emission control system may include such parts as the carburetor or fuel injection system and catalytic converter. Also included may be hoses, connectors and other emission-related assemblies.

MANUFACTURER’S EMISSION CONTROL

SYSTEM WARRANTY COVERAGE:

Your 2010 and later outboard engine is warranted for a minimum of five years or 250 hours of operation, whichever comes first, or the length of Honda Marine

Distributor’s Limited warranty, whichever is longer.

However, warranty coverage based on the hourly period is only permitted for outboard engines equipped with appropriate hour meters. If any emission-related part on your outboard engine is defective under warranty, the part will be repaired or replaced by American Honda

Motor Co., Inc.

10/04/13 15:24:16 31ZX1600_120


OWNER’S WARRANTY RESPONSIBILITY:

As the outboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. American Honda Motor Co., Inc.

recommends that you retain all receipts covering maintenance on your outboard engine, but American

Honda Motor Co., Inc. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the outboard engine owner, you should, however, be aware that American Honda Motor Co., Inc. may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for presenting your outboard engine to a Honda Marine dealer as soon as a problem exists.

The warranty repair should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact American Honda

Motor Co., Inc., Marine Division Customer Relations

Office. Please see

Contacting Honda

page 110 .

WARRANTY COVERAGE:

Honda outboard engines certified to the CARB and EPA

2010 regulations are covered by this warranty for a minimum of five years or 250 hours of operation, whichever comes first, or the length of the Honda Marine

Distributor’s Limited warranty, whichever is longer from the date of delivery to the retail purchaser. This warranty is transferred to each subsequent purchaser for the duration of the warranty period.

Warranty repairs will be made without charge for diagnosis, parts and labor. All defective parts replaced under this warranty become the property of American

Honda Motor Co., Inc. A list of warranty parts is on page

121 . Normal maintenance items, such as spark plugs and

filters, that are on the warranted parts list are warranted up to their required replacement interval only.

American Honda Motor Co., Inc. is also liable for damages to other engine components caused by a failure of any warranted part during the warranty period.

Only Honda approved replacement parts will be used in the performance of any warranty repairs and they will be provided without charge to the owner. The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine’s emission control system. If such a replacement part is used in the repair or maintenance of your engine, and an authorized

Honda Marine dealer determines it is defective or causes a failure of a warranted part, your claim for your engine

119

10/04/13 15:24:21 31ZX1600_121


may be denied. If the part in question is not related to the reason that your engine requires repair, your claim will not be denied.

TO OBTAIN WARRANTY SERVICE:

You must take your Honda outboard engine, along with your sales registration card or other proof of original purchase date, at your expense, to any Honda Marine dealer who is authorized by American Honda Motor Co.,

Inc. to sell and service that Honda Marine product during his normal business hours. Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used.

If you are unable to obtain warranty service, or are dissatisfied with the warranty service you received, contact the owner of the dealership involved. Normally this should resolve your problem. However, if you require further assistance, write or call the Honda Marine

Customer Relations Office of American Honda Motor

Co., Inc.

EXCLUSIONS:

Failures other than those resulting from defects in material or workmanship are not covered by this warranty.

This warranty does not extend to emission control systems or parts which are affected or damaged by owner abuse, neglect, improper maintenance, misuse, misfueling, improper storage, and/or collision, the incorporation of, or use of, unsuitable attachments, or the unauthorized alteration of any part.

This warranty does not cover replacement of expendable maintenance items made in connection with required maintenance service after the item’s first scheduled replacement as listed in the maintenance section of the product owner’s manual, such as: spark plugs and filters.

DISCLAIMER OF CONSEQUENTIAL DAMAGE

AND LIMITATION OF IMPLIED WARRANTIES:

American Honda Motor Co., Inc. disclaims any responsibility for incidental or consequential damages such as loss of time or the use of outboard engine, or any commercial loss due to the failure of the equipment; and any implied warranties are limited to the duration of this written warranty. This warranty is applicable only where the California or U.S. EPA emission control system warranty regulation is in effect.

120

10/04/13 15:24:30 31ZX1600_122


EMISSION CONTROL SYSTEM WARRANTY PARTS:

SYSTEMS COVERED BY THIS

WARRANTY:

Fuel Metering

Evaporative

Air Induction

Ignition

PARTS DESCRIPTION

Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure sensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensor or Air fuel ratio sensor

Portable fuel tank, Fuel cap, Fuel hoses, Primer bulb, Fuel hose joint

Air intake duct, Vapor separator, Intake manifold tuning valve (Intake air bypass control valve)

Flywheel magneto, Ignition pulse generator, Ignition coil assembly, Ignition control module, Engine control module, Crankshaft position sensor, Spark plug cap,

Lubrication system

Crankcase Emission Control

Exhaust

Valve Control System

Oil pump and internal parts

Crankcase breather tube, Positive crankcase ventilation valve, Oil filler cap

Exhaust manifold and Exhaust valves

Rocker arm oil control valve

Miscellaneous Parts Tubing, fittings, seals, gaskets, and clamps associated with these listed systems.

＊

Covered up to the first required replacement only. See the Maintenance Schedule on page 62.

121

10/04/13 15:24:40 31ZX1600_123


Canada

Distributor’s Warranty

HONDA CANADA INC., for and on behalf of Honda

Motor Co. Ltd., Tokyo, Japan, gives the following written warranty on each new marine product manufactured by Honda Motor Co. Ltd., Japan, distributed in Canada by Honda Canada Inc. and sold by authorized Honda Marine dealers.

Whenever used herein, the word ‘‘Honda’’ refers to

Honda Canada Inc. and/or Honda Motor Co. Ltd., as appropriate from the context.

HONDA WARRANTS THAT each new Honda marine product will be free, under normal use and maintenance, from any defects in material or workmanship for the relevant warranty period set forth below. If any defects should be found in a Honda marine product within the relevant warranty period, necessary repairs and replacements with a new part or the Honda equivalent shall be made at no cost to the consumer for parts and labour, when Honda acknowledges that such defects are attributable to faulty material or workmanship at the time of manufacture.

WARRANTY PERIOD RETAILED ON OR

AFTER APRIL 1, 2005:

All Honda Outboard

Models

Non-commercial use

36 Months

Commercial use

12 Months

THIS WARRANTY COVERS

a) Any Honda marine product purchased in Canada from an authorized Honda dealer which has been registered b) at the time of purchase on a form provided by Honda, which has had set-up and pre-delivery service performed by an authorized Honda dealer and which is normally operated in Canada;

Any factory installed part (except normal maintenance c) parts referred to in ‘‘THIS WARRANTY DOES NOT

COVER’’); and

Any marine product on which required maintenance services have been performed as prescribed in the

Owner’s Manual.

122

10/04/13 19:04:08 31ZX1600_124


THIS WARRANTY DOES NOT COVER

a) b)

Any repairs required as a result of collision, accident, striking any object, misuse or lack of required maintenance;

Any repairs required as a result of any attachments, c) parts or devices installed by or repairs done by a party other than an authorized Honda dealer;

Any outboard that has been operated out of water,

(Run Dry) damaging the water pump and or engine d) components due to insufficient cooling water.

Any marine products modified, altered, disassembled e) or remodelled;

Normal maintenance services, including tightening of nuts, bolts and fittings and engine tune-up and the replacement of parts made in connection with normal maintenance services including filters, spark plugs and f) g) wires, fuses, belts, lubricants and other expendables susceptible to natural wear;

Outboard propeller or shear pin.

All accessories or attachments.

THE OWNER’S OBLIGATION

In order to maintain the validity of this DISTRIBUTORS

WARRANTY, the required maintenance services as set forth in the Owner’s Manual must be performed at the proper intervals and detailed receipts and records retained as proof.

TO OBTAIN WARRANTY SERVICE

You must take your Honda marine product, at your expense, during normal service hours, to any authorized

Honda Marine dealership. If you are unable to obtain or are dissatisfied with the warranty service you receive, first contact the owner of the dealership involved; this should resolve the problem. If you require further assistance, contact Honda Canada’s Customer Relations

Department at:

HONDA CANADA INC.

Visit www.honda.ca for address/contact information.

TELEPHONE: 1-888-946-6329 TOLL FREE

FAX : 1-877-939-0909 TOLL FREE

123

10/04/13 15:24:57 31ZX1600_125


REPLACEMENT PARTS AND ACCESSORY

WARRANTY

New genuine Honda replacement parts or accessories sold to a consumer or installed by an authorized Honda

Marine dealer which are not covered by the

DISTRIBUTORS WARRANTY are warranted for a period of one year from date of purchase, provided, however, that this Replacement Parts and Accessory

Warranty does not apply to any replacement parts modified, used with, or installed on a marine product for which the replacement parts were not intended. Electrical components that are not installed by the dealer (sold over the counter) are not covered by warranty.

ENTIRE WRITTEN WARRANTY

This DISTRIBUTORS WARRANTY and the

REPLACEMENT PARTS AND ACCESSORY

WARRANTY are the only and the entire written warranties given by Honda for Marine engines. No dealer or his agent or employee is authorized to extend or enlarge on these warranties on behalf of Honda by any written or verbal statement or advertisement.

DISCLAIMER

To the extent the law permits, Honda disclaims any responsibility for loss of time or use of the product, transportation or towing costs or any other indirect, incidental or consequential damage, inconvenience or commercial loss.

NOTICE TO CONSUMER

The provisions contained in these written warranties are not intended to limit, modify, take away from, disclaim or exclude any warranties set forth in or the operation of

The Consumer Products Warranties Act, 1977

(Saskatchewan), The Consumer Product Warranty and

Liability Act (New Brunswick), The Consumer

Protection Act (Quebec), or any other similar provincial or federal legislation.

124

10/04/13 15:25:02 31ZX1600_126

INDEX

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

. 33

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

. 36

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

. 82

ARE YOU READY TO GET UNDERWAY?

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

. 37

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

Will Not Charge

. 104

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

. 96

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

. 37

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

. 39

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

. 28

COMPONENT AND CONTROL LOCATIONS

CONSUMER INFORMATION

........

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

. 13

. 110

CONTROL AND FEATURE IDENTIFICATION

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

. 12

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

. 17

CONTROLS AND FEATURES

CRUISING

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

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

. 35

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

. 12

. 53

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

. 110

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

. 32

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

. 31

Distributor’s Limited Warranty ...................................

. 113

Distributor’s Warranty ................................................

. 122

Electric Starter Will Not Operate ............................

. 91, 96

Emergency Stop Switch Clip and Emergency Stop

Switch

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

. 21

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

. 17

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

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

. 24

. 104

Emission Control System Warranty ............................

. 118

Engine

Cover

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

. 30

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

. 65

Oil

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

. 66

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

. 68

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

. 66

Recommendations

OVERHEATS

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

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

. 69

. 95

WILL NOT START ..................................................

. 92

125

10/04/13 15:25:08 31ZX1600_127

INDEX

Fast Idle Button

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

. 23

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

. 27

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

. 19

Fuel

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

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

. 40

. 36

Fuel

RECOMMENDATIONS

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

. 77

Fuse Replacement

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

. 76

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

. 96

FUSES ...........................................................................

. 96

Gearshift/Throttle Control Lever

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

. 22

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

. 18

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

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

. 25

. 51

HARD STARTING OR STALLS AFTER

STARTING ...............................................................

. 94

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

. 88

Honda Publications .....................................................

. 110

Ignition Switch

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

. 20

Side-Mount Type

Top-Mount Type

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

. 17

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

. 24

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

. 7

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

. 33

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

. 31

IS YOUR OUTBOARD MOTOR

READY TO GO?

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

. 37

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

. 70

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

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

. 60

. 62

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

. 29, 65

Malfunction Indicator ...................................................

. 33

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

. 57

126

10/04/13 15:25:12 31ZX1600_128

INDEX

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

. 34

OIL PRESSURE INDICATOR GOES OFF AND

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

. 98

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

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

. 39

. 35

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

. 7

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

OVERHEAT INDICATOR COMES ON AND

. 34

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

. 99

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

. 29

Power Trim/Tilt Switch

Propeller Replacement

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

. 28

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

. 82

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

. 75

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

. 89

Rev Limiter ....................................................................

. 36

SAFE OPERATING PRECAUTIONS

SAFETY LABEL LOCATION

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

. 39

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

. 9

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

. 103

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

. 59

SHALLOW WATER OPERATION

Spark Plug Service

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

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

. 56

. 72

SPARE EMERGENCY STOP SWITCH CLIP

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

. 61

Specifications

Star Label

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

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

. 109

. 107

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

. 41

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

. 44

Side-Mount Type

Top-Mount Type

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

. 41

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

. 46

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

. 52

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

. 49

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

. 49

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

. 50

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

. 84

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

. 88

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

. 84

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

. 84

Engine oil

Fuel

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

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

. 87

. 85

SUBMERGED OUTBOARD MOTOR .....................

. 101

127

10/04/13 15:25:15 31ZX1600_129

INDEX

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

. 31

TAKING CARE OF UNEXPECTED PROBLEMS ....

. 91

TECHNICAL AND CONSUMER

INFORMATION .....................................................

. 103

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

. 103

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

. 59

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

. 29

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

. 61

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

WITH OUTBOARD MOTOR INSTALLED

. 90

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

. 90

WITH OUTBOARD MOTOR REMOVED

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

. 90

Trim Meter (optional equipment)

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

. 30

TRIM TAB ADJUSTMENT

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

. 31

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

. 64

Trolling Speed Control ..................................................

. 55

Warranty Statements ...................................................

Water Separator Buzzer

. 113

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

. 35

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

. 101

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

. 101

Water Separator Inspection and Service .......................

. 80

128

31ZX1601

00X31-ZX1-6010

EM3

AH

英

N HC 300.2010.11

Printed in Japan

Includes US and Canadian Models

PANTONE 288 CVC DIC F101 BLACK

BF115D

Honda BF115 D Outboard motor Owner's Manual 131 Pages

Honda BF115 D 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

US, Puerto Rico, and US Virgin Islands Types

9

Canadian Types

10

Canadian Types

11

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

12

COMPONENT AND CONTROL LOCATIONS

13

Remote Controls (optional equipment)

Side-Mount Control Type

Panel-Mount Control Type

Control Panel

(for Panel-Mount Type)

14

Top-Mount Type

(Single Outboard Motor Type)

(Dual Outboard Motor Type)

Control Panel

(Top-Mount Single Type)

(for Top-Mount Dual Type)

15

Instruments

(optional equipment)

Tachometer Digital Speedometer Trolling Control Switch Panel

Trim Meter Digital Tachometer

16

CONTROLS

Side-Mount Type

Ignition Switch

Emergency Stop Switch Clip and

Emergency Stop Switch

17

Gearshif t/Throttle Control

Lever

18

Fast Idle Lever

19

Panel-Mount Type

Ignition Switch

20

Emergency Stop Switch Clip and

Emergency Stop Switch

21

Gearshif t/Throttle Control

Lever

22

Fast Idle Button

23

Top-Mount Type

Ignition Switch

Emergency Stop Switch Clip and

Emergency Stop Switch

24

Gearshif t/Throttle Control

Lever

25