Honda BF40A Owner's Manual 113 Pages
Honda BF40A is a powerful and reliable outboard motor that is perfect for a variety of boating applications. With its 40 horsepower engine, the BF40A provides plenty of power for getting on plane quickly and cruising at high speeds. The BF40A also features a number of advanced features that make it easy to operate and maintain, including a fuel-injected engine for improved fuel efficiency and performance, and a maintenance-free battery for hassle-free starting. Whether you're a seasoned boater or a first-time buyer, the Honda BF40A is a great choice for anyone looking for a high-quality outboard motor.
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BF40A / 50A
Owner’s
Manual
The engine exhaust from this product contains chemicals known to the State defects or other reproductive harm.
w a
Thank you for purchasing a Honda
Outboard Motor.
This manual describes the operation and maintenance of the Honda
BF40A and BFSOA Outboard
Motors.
All information in this publication is based on the latest product informa- tion available at the time of printing.
Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the Outboard Motor and it must stay with the Outboard
Motor if resold.
READ THIS OWNER’S MANUAL
CAREFULLY. Pay special attention to these symbols and any instructions that follow.
B
You WILL be
KILLED or SERIOUSLY HURT if you don’t follow instructions.
B You CAN be
KILLED or SERIOUSLY HURT if you don’t follow instructions.
-
You CAN be HURT if you don’t follow instructions.
(
NOTICE
1 Your outboard motor or other property can be damaged if you don’t follow instructions.
Honda Outboard Motors are designed to give safe and dependable service if operated according to instructions.
Operating this Outboard Motor requires special effort on your part to ensure your safety and the safety of others.
-
Careless oDeration or misuse may cause iijury or property damage. Read and understand this owner’s manual before operating the Outboard
Motor.
If a problem should arise, r)r if you have any questions about your
Outboard Motor, see an authorized
Honda Marine dealer.
HONDA MOTOR CO., LTD. 1994,
ALL RIGHTS RESERVED
1
TYPES OF HONDA BF40Al50A OUTBOARD MOTORS
It may be necessary to refer to this chart for reference purposes when reading this manual.
Model
BF4OA
Type
LH
LR
LRT
XRT
Shaft Length
L
X
0
0
0 a
LR
BFSOA
LRT
XRT
0
0
TYPE CODE (example) l
L R T
TT
T = Power Trim/Tilt
Tiller
Handle l
Remote
Control
0 l l l l l
Gas Assisted Power Trim/ Tachometer
Tilt Tilt e
0 a l l
0 l l l l l
R = Remote Control
H = Tiller Handle
Trimmeter l l
X = Extra Long Shaft
L = Long Shaft c
2
IDENTIFICATION NUMBERS
RIGHTSTERNBRACKET ,,----A
>y#
Sl
.
PRODUCT IDENTIFICATION NUMBER
Record the Product Identification
Number (P.I.N.) and the Engine Serial
Number for your reference. Refer to the
Product Identification Number when ordering parts, and when making
technical or warranty inquiries (see page
ENGINE SERIAL NUMBER
The Product Identification Number is stamped on a plate and attached to the right stem bracket. The Engine Serial
Number is stamped on the cylinder block under the starter motor which is located in the front of the engine.
Product identification number:
Engine serial number:
3
CONTENTS
SAFETY LABELS .....................................................
SAFETY INFORMATION
........................................
6
7
8
TILLER HANDLE TYPE
Engine Start Button ....................................................
Shift Lever.. ................................................................
Choke Knob ................................................................
Throttle Grip ...............................................................
Throttle Opening Indicator .........................................
Throttle Friction Knob ...............................................
Engine Stop Switch ....................................................
Emergency Stop Switch Lanyard ...............................
Oil Pressure Indicator Light .......................................
Overheat Indicator Light ............................................
1 1
1 1
11
12
REMOTE CONTROL TYPE
Remote Control Lever ................................................
Neutral Release Lever ................................................
Ignition Switch ...........................................................
Emergency Stop Switch Lanyard ...............................
Choke/Fast Idle Lever ................................................
Manual Choke Knob .................................................. 18
Oil Pressure Indicator Light/Buzzer ...........................
19
Overheat Indicator Light/Buzzer ................................
19
15
16
16
17
18
REMOTE CONTROL & POWER TRIM/TILT TYPE
Power Trim/Tilt Switch (remote control lever) .......... 20
Power Tilt Switch (motor pan) ...................................
21
12
12
13
13
14
14
4
Trim Meter .................................................................
Tachometer .................................................................
Manual Relief Valve ..................................................
2 1
21
22
GAS ASSISTED TILT TYPE
Tilt Lever ....................................................................
22
CONTROLS & INSTRUMENTS (common)
Tilt Lock Lever. ..........................................................
23
Trim Tab .....................................................................
Fuel Cap/Gauge/Vent Knob .......................................
23
Anode Metal ...............................................................
24
Cooling System Indicator.. .........................................
24
Water Intakes ..............................................................
25
Transom Angle Adjusting Rod ..................................
26
27
Over-Rev Limiter .......................................................
27
Engine Cover Removal/Installation
........................... 28
Engine Oil ..................................................................
29
Fuel Level ...................................................................
30
Fuel Recommendations ..............................................
3 I
Oxygenated Fuels .......................................................
32
Propeller and Cotter Pin .............................................
Steering Friction Adjustment
(common). ...................
;;
Remote Control Friction Adjustment
......................... 34
Other Checks l
Stem Bracket.. .......................................................... l
Tool Kit ....................................................................
. Anodes .....................................................................
Fuel Tank and Vent Knob ..........................................
34
34
34
35 y
=
4
5
-
Fuel Line Connection
.................................................
35
STARTlNGTHEENGINE(T!LLER HANDLETYPE)... . 37
START!NGTHEENGINE(REMO~CO~ROL~PE)...
Emergency Starting ....................................................
. 41
44
Troubleshooting Starting Problems.. ..........................
49
Break-in Procedure .....................................................
50
TILLER HANDLE TYPE
Gear Shifting .........................................................
Steering ..................................................................
Cruising .................................................................
REMOTE CONTROL TYPE
Gear Shifting .........................................................
Cruising .................................................................
Tilting Motor
GAS ASSISTED TILT TYPE ...............................
POWER TRIM/TILT TYPE .................................
POWER TRIM/TILT TYPE
Trim Meter.. ...........................................................
Power Tilt Switch (Motor Pan) .............................
Manual Relief Valve.. ............................................
Tilt Lock Lever ......................................................
Trim Tab Adjustment
.................................................
MOTOR PROTECTION SYSTEM
Engine Oil Pressure and
Overheat Warning System.. ...................................
Over-Rev Limiter .................................................. power Trim Warning System ................................
“5:
52
53
54
55
58
Anodes ...................................................................
Shallow Water Operation ......................................
High Altitude Operation ........................................
59
60
60
6 1
62
63
65
65
66
67
68
CONTENTS
TILLER HANDLE TYPE .....................................
69
REMOTE CONTROL TYPE.. ..............................
7 1
.....................................................
72
.................................
73
.....................................................
THE IMPORTANCE OF MAINTENANCE..
75
...... 75
MAINTENANCE
SAFETY ..................................
75
EMISSION CONTROL SYSTEM INFORMATION ... 76
Tool Kit and Spare Parts.. ......................................
79
MAINTENANCE
SCHEDULE ............................
80
Engine Oil ..............................................................
82
Gear Oil .................................................................
84
Spark Plugs ............................................................
86
Battery (not included) ............................................
87
Lubrication ............................................................
88
Engine Fuel Filter ..................................................
89
Fuel Tank and Filter ..............................................
9 !
Fuse Replacement..
................................................
92
Propeller ................................................................
93
Submerged Motor ..................................................
94
.................................................................
.............................................
96
98
....................................................
SERVICE ...........................................
100
102
15. WIRING DIAGRAM .................................................
103
16. INDEX .......................................................................
106
5
1. ‘SAFETY
SAFETY LABELS
These labels are in the locations shown. They warn you of potential hazards that could seriously injure you. Read these labels carefully.
, PUCE
IN NEUTRAL BEFORE STARTINR
I 00 HOI
OPERATE WITH ENQINE COVER REMOVED.
I BE SURE THE ANYlYENTILATION
PINE IS BELOW THE
I $V&O, s”,F, TO REVERSE S”OOENL” AT “IQ”
II i
,
CHECII
OIL LEVEL BEFORE STARTING
I FL”S” YHE SYSTEM THOROUGHLY WITH FRESH WATER
AFKR EACH USE IN SALT WATEG
I ;QH;NCY STARTINQ IN!4TRUClIONS ARE ON TOP OF
_.-
,
GASOLINE@&:
6
i c
SAFETY INFORMATION
For your safety and the safety of oth- ers, pay special attention to these pre- cautions.
Operator Responsibility
l l l l l l
Know how to stop the engine quickly in case of emergency.
Understand the use of all controls.
Do not exceed the boat manufactur- er’s power recommendation, and be sure that the outboard motor is properly mounted.
Never permit anyone to operate the outboard motor without proper instruction.
Stop the engine immediately if any one falls overboard.
Do not run the motor while the boat is near anyone in the water.
Attach the emergency stop switch lanyard securely to the operator. l
Do not remove the engine cover while the engine is running. l
Before operating the outboard motor, familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.
9 Do not attempt to modify the out- l l board motor.
Always wear PERSONAL
FLOTATION DEVICE (PFD) when on board.
Do not remove any guards, labels, shields, covers or safety devices; they are installed for your safety.
Fire and Burn Hazards
Gasoline is extremely flammable, and gasoline vapor can explode. Use extreme care when handling gasoline. l l
Remove the fuel tank from the boat for refueling.
Refuel in a well-ventilated area with the engine stopped. Keep flames and sparks away, and do not smoke in the area.
1. SAFETY
l
Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank
(there should be no fuel in the filler neck). After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.
7
2. COMPONENT IDENTIFICATION (TILLER HANDLE TYPE)
THROTTLE GRIP
\
FUEL LINE
CONNECTOR
\ I
ENG1NE CoYER
OIL FILLER CAP
OIL LEVEL
DIPSTICK
LOCK
LEVER -
COOLING
SVSTIiXA
GEAR OIi
I.
(ANODE METAL)
PROPELLER
GEAR OIL DRAIN PLUG
8
GEAR SHIFT LEVER
I
----
cm. PRRSSURE
INDICATOR
-..I_-.-- ---
LIGHT
OVERHEAT
INIMCATOR
LIGHT
’ \
\
TH
FR kOTI’LE
ICTION
\
ENGINE START
N
< LEVER
‘YATER INTAKE
EMERGENCY
/
STOP SWITCH
CLIP
I
STOP SWITCH
LANYARD
SPARE EMERGENCY
STOP SWITCH CLIP
2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE)
FUEL LINE
CONNECTOR
ENGINE
COVER
POWER TILT
SWITCH
OIL FIL;LER CAP
OIL LEVEL
DIPSTICK
\
CHOKE KNOB
\ I
STEERING
PLATE x k
TILT
LOCK
I I
COOLING
SYSTEM
INDICATO
LE
/STERN
BRACKET
POWER TRIM/TILT
GWITCH
/
Jz.,.“II.Y “I”
DRAIN BOLT
ACCESS COVER
LEVEL PLUG
ETAL)
GEAR dH
DRAIN PLUG
&HAUST
\’
PROPELLER
WASH PLUG
PORT
(Flush plug)
NEUTRAL
OVERHEAT
INDICATOR
LIGHT
CHOKE/FAST
IDLE LEVER
\ PLATE
\
WAT ER INTAKE
EMERGENCY Sl rap
SWITCH LANYARD
EMERGENCY
1
EMERGENCY STOP
SWITCH CLIP
9
2. COMPONENT IDENTIFICATION
FUEL G.AUGE
VENT KNOB
/
POWER TRIM/TILT TYPES
FUEL
TACHOMETER
10
I
PRIMER BULB
FUEL HOSE CONNECTOR
(FEMALE)
TRIM METER
Engine Start Button
R
(reverse)
Shift Lever
3. CONTROLS (TILLER HANDLE TYPE)
Choke Knob
(reveEe)
N
ENGINE START
BUTTON
Move the gearshift lever to the N
(neutral) position before starting. The engine will not start unless the gearshift lever is in the N (neutral) position.
SHIti LEVER
There are three gearshift lever posi- tions.
F (forward): The boat moves forward.
N (neutral): The transmission gears are disengaged from the engine.
R (reverse): The boat reverses.
CHOKi KNOB
When the engine is cold, pull the choke knob. A rich fuel mixture is provided to the engine by pulling the choke knob.
11
3. CONTROLS (TILLER HANDLE TYPE)
Throttle Grip
Throttle Opening Indicator
THROTTLE OPENING INDICATOR
Throttle Friction Knob
THROTTLE GRIP
Turn the grip clockwise or counter- clockwise to adjust the engine speed.
Turning the grip in the direction shown
by
the arrow increases engine speed.
The curve on the grip indicates throttle opening.
RELEASE
Use the throttle friction knob to set the throttle grip at a certain position while cruising. Turning the friction knob clockwise sets the throttle grip, and it is released by turning the friction knob counterclockwise.
12
Engine Stop Switch
3. CONTROLS (TILLER HANDLE TYPE)
Emergency Stop Switch Lanyard
ENGINE STOP
\
ENGINE STOP SWITCH
Push the engine stop switch to stop the engine.
EMERGENCY STOP SWITCH CLIP
The emergency stop switch lanyard is provided to stop the engine immedi- ately in the event the operator should fall overboard or away from the con- trols.
The emergency stop switch clip must be engaged with the engine stop switch or the engine will not start.
When the emergency stop switch clip becomes disengaged with the engine stop switch the engine will stop imme- diately.
EMERGENCY STOP SWITCH LANYARD
Attach the emergency stop switch lan- yard securely to the operator when operating the outboard motor.
13
3. CONTROLS (TILLER HANDLE TYPE)
Oil Pressure Indicator Light r
SPARE EMERGENCY
STOP SWITCH CLIP
Overheat Indicator Light
A spare emergency stop switch clip is provided near the engine stop switch.
OIL PRESSURE INDICATOR LIGHT
The green oil pressure indicator light is normally ON when the outboard motor is running.
When the engine oil level is low or the engine lubrication system is faulty, the green oil pressure indicator light turns
OFF and the engine speed decreases gradually.
OVERHEAT INDICATOR LIGHT
When the engine cooling system is faulty, the red overheat indicator light turns ON and the engine speed decreases gradually.
14
3. CONTROLS (REMOTE CONTROL TYPE)
Remote Control Lever
OTTLE OPENING c
The remote control lever controls gear selection and throttle opening posi- tions.
It is necessary to pull up the neutral release lever to operate the remote control lever.
F (forward):
Moving the lever to the F position
(approximately 30’ from the N position) will engage the forward gear. Moving the lever further from the F position will increase the throttle opening and the boat for- ward speed.
REMOTE CONTROL LEVER
R (reverse):
Moving the lever to the R position
(approximately 30” from the N position) will engage the reverse gear.
Moving the lever fur-then into the
R position will increase the throttle opening and the boat reverse speed.
N (neutral):
The engine idles and the transmis- sion gears are disengaged.
15
3. CONTROLS (REMOTE CONTROL TYPE)
Neutral Release Lever
Ignition Switch
START
The neutral release lever is on the remote control lever to prevent an accidental gear engagement.
The remote control lever will not engage forward or reverse gear unless the neutral release lever is pulled up.
The remote control box is equipped with a key type ignition switch.
Key
positions:
START
To activate the starter motor and start the engine. (the remote control lever must be in the neutral position)
ON
To run the engine after starting (the battery will discharge if the key is left in this position with the engine not running).
OFF
To stop the engine
OFF).
(IGNITION
To prevent the battery from dis- charging, keep the key in the
OFF position when the engine is not run- ning.
16
Emergency Stop Switch Lanyard
EMERGENCY
3. CONTROLS (REMOTE CONTROL TYPE)
I
SWITCH CLIP
The emergency stop switch lanyard is provided to stop the engine immedi- ately in the event the operator should fall overboard or away from the con- trols.
The emergency stop switch clip must be engaged with the emergency engine stop switch or the engine will not start.
When the emergency stop switch clip becomes disengaged from the emer- gency engine stop switch the engine will stop immediately.
The emergency engine stop switch should not he used to normally stop the engine. Use the ignition switch to normally stop the engine.
Attach the emergency stop switch lan- yard securely to the operator when operating the outboard motor.
SPARE EMERGENCY
STOP SWITCH CLIP
A spare emergency stop switch clip is provided on the remote control box.
17
3. CONTROLS (REMOTE CONTROL TYPIE)
Choke/Fast Idle Lever
N
(neutral)
A CHOKE
MAXIMUM FAST IDLE
Manual Choke Knob
EST POSITION
The choke/fast idle lever provides two functions:
1. Electric choke solenoid activation for easy engine start up.
2. Engine fast idle.
The choke/fast idle lever will not move unless the remote control lever is in the N (neutral) position.
Conversely, the remote control lever will not move unless the choke/fast idle lever is in the lowest position.
’ IDLE LEVER
Lift and hold the choke/fast idle lever up fully, this will provide a rich fuel mixture and the correct fast idle.
Gradually lower the choke/fast idle lever to the lowest position to decrease the choke and fast idle.
CHOKE KNOB
A manual choke knob is provided on the right side of the motor which can be used in the event the battery is dis- charged. Pull the manual choke knob, and a rich fuel mixture will be provid- ed to the engine.
18
Oil Pressure Indicator Light/Buzzer
3XONTROLS(REMOTECONTROLTYPE)
Overheat Indicator Light/Buzzer
.
The green oil pressure indicator light turns OFF and the buzzer sounds when the oil level is low and/or the engine lubrication system is faulty.
The engine speed slows down gradual-
IY-
The red overheat indicator light turns
ON and the buzzer sounds when the engine cooling system is faulty. The engine speed slows down gradually.
19
3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)
Power Trim/Tilt Switch (remote control lever)
Power Ikim
Press the power trim/tilt switch on the remote control lever to adjust the motor trim angle of 0” to 20” to main- tain proper boat trim. The power trim/tilt switch located on the remote control lever can be operated while the boat is under way or while stopped.
By using the power trim/tilt switch the operator can change the trim angle of the motor to achieve maximum boat acceleration, speed, stability and maintain optimum fuel consumption.
Power Tilt
Press the power trim/tilt switch on the remote control lever to adjust the motor tilt angle of 20” to 60”.
By using the power trim/tilt switch the operator can change the tilt angle of the motor for shallow water operation, beaching, launching from a trailer, or mooring.
I I
w Excessive trim/tilt angle during operation can cause the pro- peller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump.
XRTA type outboard
Power Trim
Do not trim this engine when you are using a large amount of throttle opening. If you do try to trim the en- gine, under certain conditions, pro- peller thrust may override the power trim hydraulics and cause the engine to return to the transom angle adjust- ing rod. (Full “in” position)
Power Tilt
Press the power tilt switch on the remote control lever to adjust the motor tilt angle of 20” to 60”.
By using the power tilt switch the op- erator can change the tilt angle of the motor for shallow water operation, beaching, launching from a trailer, or mooring.
20
3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)
Power Tilt Switch (motor pan) Trim Meter Tachometer
POWER TILT SWITCH
The power tilt switch located on the motor pan is a conveyance switch for tilting the motor for trailering, or pre- forming outboard maintenance. This power tilt switch should only be oper- ated with the boat being stopped and motor off.
TRIM METER
The trim meter has a range of 0” to 20” and indicates the trim angle of the out- board motor. Refer tothe trim meter when using the power trim/tilt switch to achieve proper boat performance.
TACHOMETER
The tachometer shows the approxi- mate engine speed in revolutions per minute. Refer to the tachometer when using the power trim/tilt switch to achieve proper boat and motor perfor- mance.
21
3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)
Manual Relief Valve
If the power trim/tilt switch will not tilt the outboard motor, the motor can be manually tilted up or down by opening the manual relief valve. To tilt the outboard motor manually, turn the manual valve under the left stem bracket no more than 1 or 2 turns counterclockwise using a screw driver.
After tilting the motor, turn the manual relief valve clockwise securely.
The manual relief valve must be tight- ened securely before operating the motor or the motor could tilt up when operating in reverse.
LEFT STERN BRACKET
MANUAL
POWER (To rele=)
MANUAL-RELIEF VALVE
Do not turn this screw. If this screw is turned hydraulic oil will bleed out of the power trim/tilt system. Should this happen it will be necessary to consult your authorized Honda
Marine dealer and have the system refilled.
Tilt Lever (GAS ASSISTED
TYPE)
VER
Moving the tilt lever to the FREE position allows the motor to be tilt- ed and moving the tilt lever to the
LOCK position locks the motor in the desired position. Use the tilt lever to temporarily tilt the motor when the boat is operating in shallow water, or mooring in shallow water. The tilt lever must be in the LOCK position before operating the motor or the motor could tilt up when operating in reverse.
22
Tilt Lock Lever
m
.
Use the tilt lock lever to hold the motor in the highest tilt position when the boat is moored for a long time.
Tilt the motor up as far as it will go then move the tilt lock lever into the lock position and gently lower the motor.
3. CONTROLS & INSTRUMENTS
(common)
Trim Tab
Distribute the load evenly in the boat and run the boat in straight course at full throttle. Slightly turn the steering wheel or tiller handle for both right and left turns to determine if an equal amount of effort is required. If adjust- ment is necessary loosen the tighten- ing bolt and turn the trim tab right or left. Make small adjustments at a time and retest. Incorrect trim tab adjustment can cause adverse steering.
The trim tab also functions as an anode.
PROPELLER
When making a turn, if an unequal amount of effort is required to turn the steering wheel or tiller handle right or left, adjust the trim tab so that an equal amount of effort is required.
23
3. CONTROLS & INSTRUMENTS
(common)
Anode Metal
Cooling System Indicator
The anodes are made from a sacrificial material which helps to protect the outboard motor from corrosion.
ANODE
(stern bracket)
(NOTICEJ Painting or coating the anodes will lead to rust and corro- sion damage to the outboard motor.
COOLING SYSTEM INDICATOR
The cooling system is monitored here to make sure cooling water is circulat- ing through the engine.
24
Water Intakes
The engine cooling water is drawn into the water pump through these water intakes.
WATER INTAKES
3. CONTROLS & INSTRUMENTS (common)
25
3. CONTROLS & INSTRUMENTS
(common)
Transom Angle Adjusting Rod
TRANSOM ANGLE
TO CHANGE ADJUSTING ROD
UNLOCKED
POSITION
TRANSOMANGLE
ADJUSTINGROD
The transom angle adjusting rod is used to adjust the motor angle to achieve the correct boat trim. There are 5 adjustment holes located in the stem bracket.
Push.in and turn the transom angle adjusting rod up to remove. To install insert into the proper hole and turn down to lock. After installation pull the transom angle adjusting rod out- ward to be sure it is locked in place.
Start with the transom angle adjusting rod in the hole closest to the boat tran-
26
T-0 LOCK
L~~KEDP;OSITION
som, lower the motor and operate the boat at full speed. If the bow is exces- sively low stop the boat. Tilt the motor up and raise the transom angle adjust- ing rod one more hole away from the transom and retest. The optimum boat trim is when the boat is parallel with the water.. The transom angle adjust- ing rod stops the motors forward movement.
The motor should never be operated with the transom angle adjusting rod removed.
*
.
Fuel Cap/Gauge/Vent Knob
VENTKNOB
GAUGk FUELFiLLER'CtiP
The fuel gauge is part of the fuel cap.
The fuel cap vent knob controls air entering and leaving the fuel tank.
When refilling the fuel tank, turn the vent knob counterclockwise to the open position and remove the fuel cap.
Before transporting, storing or refill- ing the fuel tank inspect the condition of the fuel cap gasket and replace if necessary.
3. CONTROLS & INSTRUMENTS
(common)
Before transporting or storing the fuel tank turn the vent knob fully clock- wise to the closed position.
Anytime the fuel tank is in the boat with the vent knob closed, discon- nect the fuel hose connector from the outboard motor (refer to page
B Gasoline is extremely flammable, and gaso- line vapor can explode, causing serious injury or death. Do not smoke or allow’flames or sparks in your working area. KEEP
OUT OF REACH OF CHILDREN.
Over-Rev Limiter
This outboard motor is equipped with an engine over-rev limiter which limits the maximum engine rpm. This over- rev limiter protects the engine from mechanical damage.
The over-rev limiter may be activated by putting the propeller in a light load condition or propeller ventilation.
When the over-rev limiter is activated the engine rpm will become unstable or erratic. Should this occur reduce the throttle opening and wait for the engine rpm to stabilize then increase the throttle opening.
On the power trim/tilt type motors lower the trim angle on high speed turns to re- duce the possibility of propeller ventila- tion.
27
4. PRE-OPERATION CHECKS
Engine Cover Removal/Installation
(FRONT) (REAR)
ENGINE COVER
LATCHES
To remove, release the front and rear engine cover latches and remove the engine cover.
To install, position the engine cover over the engine and hook and lpck the front and rear latches.
28
.
,
Engine Oil
Engine oil is a major factor affecting engine performance and service life.
-1 Running the engine with insufficient oil can cause serious engine damage.
Recommended oil
Use high-detergent, premium quality
4-stroke engine oil, certified to meet or exceed U.S. automobile manufac- tures’ requirements for American
Petroleum Institute (API) Service
Classification SG, SH. Engine oils classified SC, SH will show these designations on the container.
Select the appropriate viscosity for the average temperature in your area.
SAE low-30 is recommended for gen- eral, all-temperature use (BF35A).
SAE 5W-30 is recommended for gen- era]. all-temperature use (BF40A/50A).
API Service Grade: Use a Fuel
Efficient SG, SH oil.
4. PRE-OPERATION CHECKS
NOTE: This oil is usually identified by words such as: “Energy Conserving
Il.” “Gas Saving, ” “Fuel Saving,” etc.
Inspection
1. Position the outboard motor verti- cally, and remove the engine cover.
2. Remove the oil level dipstick and wipe with a clean rag.
3. Reinsert the dipstick all the way in, then pull it out and read the level. If the oil registers near or below the lower limit mark, remove the oil filler cap and fill to the upper level mark with the recommended oil.
INOTICE] DO not overfill. Excessive oil can damage the engine.
4. Reinstall the oil filler cap and tight- en securely.
5. Install the engine cover and lock it securely.
When the engine oil is contaminated or discolored, replace with fresh engine oil
(refer to page 82 for oil capacity,
replacement interval and procedure).
29
4. PRE-OPERATION CHECKS
Fuel Level
SAFE FILL LEVEL
VENT KNOB
Check the fuel gauge and refill the tank to the SAFE FILL level mark if necessary.
Fuel tank capacity : 6.6 US gal. (25 lit)
B Gasoline is extremely flammable, and gaso- line vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP
OUT OF REACH OF CHILDREN.
FUEL CAP
Refilling
Remove the fuel tank from the boat for refilling. Turn the vent knob coun- terclockwise to the open position and remove the fuel cap.
Refuel in a well-ventilated area. Fill the fuel tank up to the SAFE FILL level mark only. Inspect the condition of the fuel cap gasket and replace if necessary.
After refilling, install and tighten the fuel cap securely. Turn the vent knob clockwise to the closed position.
Return the fuel tank to the boat.
30
i
i
Fuel Recommendations
Use unleaded gasoline with a pump octane rating of 86 or higher.
These outboard motors are 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 oillgaso- line mixture. Avoid getting dirt or water in the fuel tank.
Occasionally you may hear light “spark knock” or “ping- ing” (metallic rapping noise) while operating under heavy loads. This is no cause for concern.
If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda Marine dealer.
JNOTICE] Running the engine with persistent spark knock or pinging can cause engine damage.
Running the engine with persistent spark knock or ping- ing is misuse, and the Distributor’s Limited Warranty does not cover parts damaged by misuse.
4. PRE-OPERATION CHECKS
31
4. PRE-OPERATION CHECKS
Oxygenated Fuels
Some conventional gasolines are being blended with alco- hol or an ether compound. These gasolines are collec- tively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.
If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/provinces require this information to be posted on the pump.
The following are the EPA approved percentages of oxy- genates:
ETHANOL -
(ethyl or grain alcohol) 10% by volume
You may use gasoline containing up to
10% ethanol by volume. Gasoline con- taining ethanol may be marketed under the name “Gasohol”.
MTBE
- (Methyl Tertiary Butyl Ether) 15% by volume
You may use gasoline containing up to
15% MTBE by volume.
32
METHANOL
- (methyl or wood alcohol) 5% by volume
You may use gasoline containing up to
5% methanol by volume, as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system.
Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system.
If you notice any undesirable operating symptoms, try an- other service station, or switch to another brand of gaso- line.
Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.
Propeller and Cotter Pin
4. PRE-OPERATION CHECKS
Steering Friction Adjustment
(common)
TO DECREASE
COTTER PIN
(stainless steel)
/
Propeller
Check the propeller blades for damage, wear or deformation and replace if necessary. Never operate the outboard motor with a damaged pro- peller.
Carrying a spare propeller, propeller nuts, and cotter pins are common practice. If the propeller is damaged and no spare propeller is available, consult an authorized Honda Marine dealer.
(Refer to page 93 for propeller change
information)
I -
PROPELLER
Cotter Pin
Check the cotter pin for damage and correct installation. If the cotter pin needs replacement use only a new genuine Honda stainless steel cotter pin.
Operate the steering wheel or tiller handle right and left and check for the amount of drag felt.
Adjust the steering friction adjuster so that a slight amount of drag is felt. The steering should move smoothly and freely.
33
4. PRE-OPERATION CHECKS
Remote Control Friction
Adjustment
TO INCREASE
TO DECREASE
FRICTION
Operate the remote control lever into forward and reverse gears and check for the amount of drag felt.
Adjust the remote control friction adjuster so that a slight amount of drag is felt. The remote control lever should move smoothly and freely.
Other Checks
1
2
Check the following items:
1. The fuel hose for kinking, collaps- ing or loose connections.
2. The stem bracket for damage and mounting bolts for proper torque.
3. The tool kit contents. Compare your tool kit contents against the tool kit illustration above. Replace any missing items.
4. The anodes for damage, looseness or excessive corrosion.
The anodes help to protect the out- board motor from corrosion any time they are exposed directly to the water.
(5
10 x 12 mm WRENCH
I.
8 InnI WRRNCH cs
3
FLAT SCREWDRIVER
PHILLIPS
SCREWDRIVER
,IL CHECK
SCREWDRIVER
STARTER ROPE c
PLIERS
D, p7&&
II x 19 mm WRENCH
Replace anodes when they are visibly reduced in size or crumble easily.
@@%I Painting or coating the anodes will lead to rust and corro- sion damage to the outboard motor.
The following materials should be kept with the boat:
1. Owner’s Manual.
2. Tool Kit.
3. Spare engine oil, spark plugs, pro- peller, propeller cotter pins and nut.
4. Required information regarding boating laws and regulations.
34
. f
Fuel Tank and Vent Knob
VENT KNOB
5. STARTING THE ENGINE
Fuel Line Connection
FUEL HOSE CONNECTOR
The fuel tank must be properly se- cured in the boat. This will protect the fuel tank from mechanical dam- age caused by the fuel tank shifting.
The fuel tank must be in a well venti- lated area to reduce the chance of a gasoline vapor explosion. Avoid di- rect sunlight on the fuel tank.
Due to the fuel pump capacity, do not place the fuel tank more than 6 feet away from the motor or lower than 3 feet below the outboard end fuel hose connector.
1. Open the fuel tank vent by turn- ing the vent knob at least 2 or 3 turns counterclockwise.
Allow the air pressure inside the fuel tank to equalize with the outside air. With the vent open, air can en- ter the fuel tank to displace the fuel as the fuel level goes down.
2. Remove the fuel cap and inspect the condition of the fuel cap and gasket. Replace the fuel cap or gasket if they are cracked. dam- aged or leak fuel.
(FUEL TANK END) \
Inspect the fuel hose, and the O-ring seals in the fuel hose connectors. Re- palce the fuel hose. or fuel hose con- nectors if they are cracked, damaged or leak fuel. Be sure the fuel hose is not kinked.
I _ Connect the fuel hose connector to the fuel tank. Be sure the fuel hose connector is securely snapped in place.
35
5. STARTING THE ENGINE
FUEL HOSE CONNECTOR
OUTLET END
(MOTOR)
TBOARD END)
2. Connect the fuel hose connector to the outboard motor. Install the outboard end fuel hose connector with the clip toward the outside.
Be sure the fuel hose connector is securely snapped in place.
1 NOTICE 1 If the outboard end
fuel hose connector is forcibly in- stalled in the reversed direction, the fuel hose connector O-ring seal can be damaged. A damaged
O-ring seal can cause a fuel leak.
3. Hold the primer bulb so that the outlet end is higher than the inlet end. The arrow on the primer bulb points upward. Squeeze the primer bulb several times until it feels firm, indicating that fuel has reached the carburetors. Check for fuel leaks and repair any leaks before starting the motor.
Do not squeeze the primer bulb when the motor is running because this could cause the carburetors to overflow.
36
5. STARTING THE ENGINE (TILLER HANDLE TYPE)
\
ENGINE
STOP SWITCH
SPARE EMERGENCY
STOP SWITCH CLIP
.
EIVmnwm~ I
SToP
EMERGENCY STOP
SWITCH LANYARD
pEii5q
The propeller must be lowered into the water. Running the outboard motor out of the water will damage the water pump and overheat the engine.
1. Engage the emergency stop switch clip located at one end of the emer- gency stop switch lanyard with the engine stop switch. Attach the oth- er end of the emergency stop switch lanyard securely to the operator.
A spare emergency stop switch clip is provided near the engine stop switch.
m If the operator does not attach the emergency stop switch lanyard, and is thrown from his seat or out of the boat, the out-of-control boat can seri- ously injure the operator, pas- sengers, or bystanders. Always properly attach the lanyard before starting the motor.
GEAR SHIh LEVER
2. Move the gearshift lever to the N
(neutral) position.
The engine will not start unless the gearshift lever is in the N (neutral) position.
37
5. STARTING THE ENGINE (TILLER HANDLE TYPE)
THROTTLE GRIP
3. Align the engine start symbol
” o ” on the throttle grip with the pointer ” ) ” on the tiller handle.
4. When the engine is cold or ambient temperature is low pull the choke knob.
5. Press the start button and start the engine. The starter motor con- sumes a large amount of current.
Do not run it continuously for more than 5 seconds at a time. If the engine does not start within 5 sec- onds wait at least 10 seconds before using the starter motor again.
m Do not press the start hut- ton while the engine is running.
This can damage the starter motor and flywheel.
38
5. STARTING THE ENGINE (TILLER HANDLE TYPE)
6. If it was necessary to use the choke knob to start the engine, slowly return it to its initial position. Turn the throttle grip in the SLOW direction to a position where the engine does not stall.
(each side)
7. After the engine starts, verify water is flowing through the cooling system by monitoring the cooling system indicator.
The amount of water coming out of the cooling system indicator will vary due to thermostat operation. Stop the engine if water does not come out of the cooling system indicator or if you see steam. Check the water intake screens and the cooling system indicator discharge port and if necessary remove any obstructions. If the problem continues, contact your closest authorized Honda Marine dealer.
-1 R,, nning the outboard motor with an obstruc-
tion in the cooling system can damage the water pump and overheat the engine.
39
5. STARTING THE ENGINE (TILLER HANDLE TYPE)
OIL PRESSURE
9. Warm up the engine as follows:
Above 41 “F (5°C) - run the engine for 2 or 3 minutes.
Below 41°F (5°C) - run the engine for at least 5 minutes at approximately
2,000 ‘pm.
Failure to completely warm up the engine will result in poor engine performance.
NORMAL: GREEN LIGHT ON
ABNORMAL: GREEN LIGHT
BLINKING OR OFF
8. With the engine running, check to see if the green engine oil pressure indicator light turns ON.
Stop the engine if the oil pressure indicator light does not turn ON.
Check the engine oil level (see page
29). If the oil level is normal and
the oil pressure indicator light does not turn ON, contact your closest authorized Honda Marine dealer.
EMERGENCY
5. STARTING THE ENGINE (REMOTE CONTROL TYPE)
N
(neutrali
EMERGENCY
.
-1 ’ The propeller must be lowered into the water. Running the outboard motor out of the water will damage the water’pump and over- heat the engine.
1. Engage the emergency stop switch clip located at one end of the emer- gency stop switch lanyard with the emergency engine stop switch.
Attach the other end of the emer- gency stop switch lanyard securely to the operator.
cismnm
not attach the emergency stop switch lanyard, and is thrown from his seat or out of the boat, the out-of-control boat can seri- ously injure the operator, pas- sengers, or bystanders. Always properly attach the lanyard before starting the motor.
The engine will not start unless the emergency stop switch clip is engaged with the emergency engine stop switch.
A spare emergency stop switch clip is provided on the remote control box.
2. Move the control lever to the N
(neutral) position.
The engine will not start unless the control lever is in the N (neutral) position.
41
5. STARTING TfIE ENGINE (REMOTE CONTROL TYPE)
ON
FAST
3. When the engine is cold or the ambient temperature is low, lift the choke/fast idle lever up fully. This will provide a rich fuel mixture.
When the engine is warm, it may be necessary to raise the choke/fast idle lever slightly. Hold it in this position.
The choke/fast idle lever will not move unless the control lever is in the N
(neutral) position.
42
4. Holding the choke/fast idle lever in position, turn the ignition key to the
START position and release the key when the engine starts. The starter motor consumes a large amount of current. Do not run it continuously for more than 5 seconds at a time.
If the engine does not start within 5 seconds wait at least 10 seconds before using the starter motor again.
engine is running. This can damage the starter motor and flywheel.
5. After starting the engine, return the lever slowly to the position where the engine does not stall and hold the lever in the position.
The control lever will not move unless the choke/fast idle lever is returned to the lowest position.
1-1 Do not turn the ignition key to the start position while the
5. STARTING THE ENGINE (REMOTE CONTROL TYPE)
-
OIL PRESSURE
INDICATOR LIGHT
.
.
INDICATOR
ABNORMAL : GREEN LIGHT BLINKING
WATER INTAKE
(each side)
6. After the engine starts, verify water is flowing through the cooling system by monitoring the cooling system indica- tor. The amount of water coming out of the cooling sys- tem indicator will vary due to thermostat operation. Stop the engine if water does not come out of the cooling sys- tem indicator or if you see steam. Check the water intake screens and the cooling system indicator discharge port and if necessary remove any obstructions. If the problem continues, contact your closest authorized Honda Marine dealer.
1-1 Ru nning the outboard motor with an obstruc-
tion in the coolingsystem can damage the water pump and overheat the engine.
7. With the engine running, check to see if the green engine oil pressure indicator light turns ON.
Stop the engine if the oil pressure indicator light does not
turn ON. Check the engine oil level (see page 29). If the
oil level is normal and the oil pressure indicator light does not turn ON, contact your closest authorized Honda
Marine dealer.
8. Warm up the engine as follows:
Above 41°F (5°C) - run the engine for 2 or 3 minutes.
Below 41’F (5°C) - run the engine for at least 5 minutes at approximately 2,000 rpm.
Failure to completely warm up the engine will result in poor engine performance.
43
5. STARTING THE ENGINE
Emergency Starting
(FRONT)
(REAR)
ENGINE COVER
LATCHES
If the electric starting system will not start the engine the engine can be started by using the pull emergency rope from the tool kit.
1. Release the front and rear engine cover latches then remove the engine cover.
6 x 25 mm
BOLTS
2. Remove the four 6 x 25 mm bolts and the three washers then remove the flywheel cover.
Do not lose the washers.
,
N
(neutral)
5. STARTING THE ENGINE
ENGINE STOP SWITCH
SHIP+ LEVER
(TILLER HANDLE TYPE)
3. Depending on what type of out- board motor you have, move the shift lever or the control lever to the
N (neutral) position.
(REMOTE CONTROL TYPE)
SPARE EMERGEN
STOP SWITCH
STOP SWITCH
CLIP
4. If your outboard motor is a tilIer handle type, engage the emergency stop switch clip, located at one end of the emergency stop switch lan- yard, with thi engine stop switch.
A spare emergency stop switch clip is provided near the engine stop switch.
45
5. STARTING
THE ENGINE
IGNITION KEY
EMERGENCY
0 u\\\ fi
EMERGENCY
STOP SWITCH
CLIP’
5. If your outboard motor is a remote control type, turn the ignition key to the ON position. Engage the emer- gency stop switch clip, located ‘at one end of the emergency stop switch lanyard, with the emergency engine stop switch.
SPAREEME~~~NCY
STOP SWITCH CLIP
A spare emergency stop switch clip is provided on the remote control box.
/ CHOKEKNOB
(TILLERHANDLETYPE)
6. If the engine is cold or the ambient temperature is low, pull the manual choke knob located on the front of the outboard motor.
ENGINE START,SYMBOL
5. STARTING THE ENGINE
n
CHOKE/FAST
‘ER
(REMOTE CONTROL TYPE)
If the fuel system is working properly, it should only be necessary to pull the engine 1 or 2 times with the choke knob out.
POIN/TER
I
THROlTLE GRIP
(TILLER HANDLE TYPE)
7. On the tiller handle type align the engine start symbol ” QI ” on the throttle grip with the painter ” ) ” on the tiller handle. On the remote control type lift the choke/fast idle lever. The choke/fast idle lever will stay up in the fast idle position.
(REMOTE CONTROL TYPE)
47
5. STARTING THE ENGINE
FLYWHEEL
8. Set the emergency starter rope knot in the notch in the flywheel and wind the emergency starter rope counterclockwise around the fly- wheel.
9. Pull the emergency starter rope lightly until resistance is felt, then pull briskly.
If the engine fails to start refer to
10.If it was necessary to use the manu- al choke knob to start the engine, slowly return it to its initial position.
11 .Slowly return the throttle grip to the SLOW position or the choke/fast idle lever to the lowest position to where the engine does not stall..
-
Exposed moving parts can causeinjury. Use extreme care when installing the engine cover. Do not oper- ate the outboard motor without the engine cover.
12.Leave the flywheel cover off and install the engine cover. Lock the engine cover latches. Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing. Contact your closest authorized Honda
Marine dealer and have the out- board motor and the electrical sys- tem checked.
48
;
;
Troubleshooting Starting Problems
SYMPTOM
Starter motor doesn’t turn over.
POSSIBLE CAUSE
1. Shift lever not in neutral position.
2. Blown fuse.
3. Weak battery.
Starter motor turns over but engine will not start.
1. Emergency stop switch clip is not engaged.
2. Out of fuel
3. Vent knob not open.
4. Primer bulb has not been squeezed.
5. Engine flooded.
REMEDY
1. Set shift lever in neutral position.
2. Replace fuse.
3. Start by using starter
1. Engage the emergency stop switch clip
2. Supply fuel.
3. Open vent knob.
4. Squeeze primer bulb to supply fuel.
5. Clean and dry spark plug.
5. STARTING THE ENGINE
49
6. OPERATION
Break-in Procedure
Break-in period 10 hours
Break-in operation allows the moving parts to wear-in evenly and thus ensures proper performance and longer outboard motor life.
Break-in your new outboard motor as follows:
First 15 minutes:
Run the outboard motor at trolling speed. Use the minimum amount of throttle opening necessary to operate the boat at a safe trolling speed.
Next 45 minutes:
Run the outboard motor up to a maximum of 2,000 to 3,000 rpm or
10% to 30% throttle opening.
Next 60 minutes:
Run the outboard motor up to maxi- mum of 4,000 to 5,000 rpm or 50% to 80% throttle opening. Short
50 bursts of full throttle are acceptable but do not operate the motor contin- uously at full throttle.
Next 8 hours:
Avoid continuous full throttle oper- ation (100% throttle opening).
DO not run the outboard motor at full throttle for more than 5 minutes at a time.
For boats that plane easily, bring the boat up on plane then reduce the throttle opening to the specified break-in settings called out above.
Gear Shifting
6. OPERATION (TILLER HANDLE TYPE)
N (neutral)
.
POINTER
Gearshift lever has 3 positions:
FORWARD, NEUTRAL, and
REVERSE.
An indicator at the base of the gearshift lever aligns with the letters E
N, and R on the motor pan.
1. Align the pointer on the tiller han- dle with the SLOW position dn the throttle grip to decrease engine speed.
INhCATOR
The throttle mechanism is designed
to
limit the throttle grip travel when operating in the
REVERSE
or NEU-
TRAL
positions. The throttle grip can only be turned to the
FAST
position when operating in forward gear.
2. Put the tilt lever in the LOCK posi- tion to prevent the outboard motor from tilting up, when operating in
3. Move the gearshift lever to engage the desired gear.
51
6. OPERATION (TILLER HANDLE TYPE)
Cruising
Steering
RIGHT TURN
LEFT TURN
F (forward)
GEARSHIFT LEVER
Move the tiller handle to the left.
Move the tiller handle to the right.
The tiller handle is moved in the oppo- site direction in which you want the boat to turn. f
FAST
THRO’l-kLE GRIP
With the gearshift lever in the F (for- ward) position, turn the throttle grip toward the FAST mark to increase speed. For optimum fuel economy, limit throttle opening to 2/3.
RELEASE
To set the throttle at a steady speed, turn the throttle friction knob clock- wise. To release the throttle grip for manual speed control, turn the friction knob counterclockwise.
52
.
Ij
NEUTRAL
RELEASE
LEVER
6. OPERATION (REMOTE CONTROL TYPE)
(forwird)
N
(neutral)
30” i
N
(neutral)
/ 30
(revfse)
1 I
PULL UP
While pulling up the neutral release lever, move the control lever 30 toward F (forward) or 30’ toward R
(reverse) to engage the desired gear.
OPENING
Moving the control lever further from
30” will increase throttle opening and boat speed.
The control lever will not move unless the neutral release lever is pulled up and choke/fast idle lever is in the lowest position.
53
6. OPERATION (REMOTE CONTROL TYPE)
Cruising
POWER TRIM/TILT
SWITC
(fohard)
N
(neutral)
I
1. On the Power trim/tilt type, press the DN portion of the power trim/tilt switch and tilt the motor to the lowest position.
2. Move the control lever from N
(neutral) 30’ toward F (forward) to engage the F (forward) gear.
Moving the control lever further from 30’ will increase the throttle opening and boat speed.
3. For optimum fuel economy, limit throttle opening to 2/3.
5
54
Tilt Lever
GEARSHIFT
LEVER
\
N
(neutral)
6. OPERATION (GAS ASSISTED TILT TYPE)
ENGINE COVER GRIP
.
.
Tilt the motor up to prevent the pro- peller and gear case from hitting the bottom when beaching or stopping in shallow water.
1. Move the gearshift lever to the
N ( neutral) position and stop the engine.
SWITCH
-TILT LEVER
2. To tilt the motor up, move the tilt lever to the FREE position, then pull the engine cover grip and raise the motor.
55
6. OPERATION (GAS ASSISTED TILT TYPE)
3. With the outboard motor tilted up to the desired position, move the tilt lever to the LOCK position to lock the motor.
4. To lower the motor back down, move the tilt lever to the FREE position, while holding the engine cover grip, then lower the motor gently. Move the tilt lever to
LOCK position.
The tilt lever must be in the LOCK position before operating the motor or the motor could tilt up when operating in reverse.
56
6. OPERATION (GAS ASSISTED SYSTEM)
.
I
TILT LOCK
LEVER
(lock Dosition)
3. Move the tilt lever to the LOCK position.
4. To lower the motor, move the tilt lever to the FREE position. Lift up on the engine cover grip and swing the tilt lock lever to the free posi- tion.
5. Lower the engine gently. Move the lever to the LOCK position.
Use the tilt lock lever to hold the motor in the highest tilt position when the boat is moored for a long time.
1. Move the tilt lever to the FREE
position (refer to page 56), then pull
the engine cover grip and tilt the motor all the way up.
2. Move the tilt lock lever to theLOCK position and lower the outboard motor slowly.
57
6. OPERATION (POWER TRIM/TILT TYPE)
XRTA type outboard
The power trim/tilt system can adjust the motor angle while cruising, or the motor tilt angle while mooring. Motor trim angle adjustment is necessary to compensate for boat load or weight distribution, water conditions, pro- peller or engine condition. The motor trim angle can be adjusted while accelerating or cruising to obtain the maximum boat sp’eed, optimum boat stability, and fuel economy. Under normal conditions, the boat will achieve optimum boat performance when the motor is running at maxi- mum rpm and the ventilation plate is level with the water.
Press either the UP or DN portion of the power trim/tilt switch and trim the motor to the best position for the cruising conditions.
The power trim/tilt system operates when the switch is pressed.and it stops when the switch is released.
58
POWER ‘“IMy>
Press UP to raise bow.
Press DN bow. to
CONTROL-LEVER \
Ii 1
INOTlcEI Excessive trim/tilt angle during operation can cause the pro- peller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive
trim/tilt angle can also damage the
water pump and overheat the engine.
To trim motor up slightly, press the
Up portion momentarily.
To trim motor down slightly, press the
DN portion momentarily.
60’
I‘
’ 20”
0’ TRIM
ANGLE
ANGLE
Decrease the trim angle on high speed turns to reduce the possibility of propel- ler ventilation.
Improper motor trim angle can result in an unstable steering condition. The power trim/tilt warning system will be activated and an intermittent buzzer sounds when the motor is trimmed excessively
5
5
.
.
MOTOR TRIMMED MOTOR TRIMMED
TOO LOW
TOO HIGH f t
I
ROUGH
WAV@S
MOTOR TRIMMED
CORRECTLY
6. OPERATION (POWER TRIM/TILT TYPE)
Trim Meter
The trim meter indicates the trim angle of the motor. Refer to the trim meter, and press the UP or
DN portion of the power trim/tilt switch to adjust the motor trim angle to achieve boat performance and stability.
BOW TOO LOW DUE TO
1. LOAD IN THE FRONT
2. MOTOR TRIMMED TOO LOW
BOW TOO HIGH DUE TO
1. LOAD IN THE REAR
2. MOTOR TRIMMED TOO HIGH
When cruising:
(A) Into a high wind, trim the motor down slightly to level the bow and improve boat stability.
(B) With a tail wind, trim the motor up slightly to raise the bow and improve boat stability.
(C) Through rough waves, do not trim the motor too low or too high to avoid an unstable steer- ing condition.
With the motor trimmed low the trim meter will read as shown. To raise the bow increase the motor trim angle by pressing the UP portion of the power trim/tilt switch.
With the motor trimmed high the trim meter will read as shown. To lower the bow decrease the motor trim angle by pressing the DN portion of the power trim/tilt switch.
6. OPERATION (POWER TRIM/TILT TYPE)
Power Tilt Switch
(Motor Pan) Manual Relief Valve
LE
POWER TILT SWITCH
The power tilt switch located on the motor pan is a convenience switch for tilting the motor for trailering, or per- forming outboard motor maintenance.
This power tilt switch should only be operated when the boat
is
stopped and the motor is off.
Do not turn this screw. If this screw is turned hydraulic oil will bleed out of the power trim/tilt system. Should thi$ happen it will be necessary to contact your closest authorized Honda Marine dealer and have the system refilled.
If the power trim/tilt switch will not tilt the outboard motor, the motor can be manually tilted up or down by operating the manual relief valve. To tilt the outboard motor manually, turn the manual relief valve under the left stem bracket no more than 1 or 2 turns counterclockwise using a screw driver.
After tilting the motor, turn the manual relief valve clockwise securely. The manual relief valve must be tightened securely before operating the motor or the motor could tilt up when operating in reverse.
:
;
60
.
LEVER
Tilt Lock Lever
Use the tilt lock lever when the boat is moored.
1. Tilt the motor up as far as it will go using the power trim/tilt switch.
2. Move the tilt lock lever to the
LOCK position and lower the out- board motor until the lock lever contacts the stem bracket (refer to
6. OPERATION (POWER TRIM/TILT TYPE)
It may be necessary to lift the engine cover grip slightly to swing the tilt lock lever into the LOCK position.
3.
To lower the motor, tilt the motor up slightly, move the tilt lock lever to the FREE position, and lower the motor to the desired position.
61
6. OPERATION
Trim Tab Adjustment
RIGHT
TIGHTENING B
The trim tab is provided to adjust for
“torque steer” which is a reaction of the propeller rotation or propeller torque. If during a high speed turn an unequal amount of effort is required to turn the boat right or left, adjust the trim tab so that an equal amount of effort is required.
Distribute the load evenly in the boat and run the boat in a straight course at full throttle. Slightly turn the steering wheel or tiller handle for both right and left turns to determine the amount of effort required.
62
If less effort is required to make left turns:
Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the left. lighten the bolt securely.
If less effort is required to make right turns:
Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the right. lighten the bolt securely.
Make small adjustments at a time and retest. Incorrect trim tab adjustment can cause adverse steering.
The trim tab also functions as a sacrifi- cial anode.
(NOTICE] Painting
or
coating the anode will lead to rust and corrosion damage to the outboard motor
6. OPERATION
(MOTOR PROTECTION
SYSTEM)
If the engine oil pressure drops and/or the engine overheats, either or both warning systems could be activated.
When activated the engine speed will decrease gradually and the green oil pressure indicator light will turn OFF and the red overheat indicator light will turn ON. A continuous buzzer will sound on the remote control type.
The engine speed can not be increased with a larger throttle opening until the malfunction is corrected. When the malfunction is corrected the engine speed will increase gradually.
(TILLER HANDLE TYPE)
INDICATOR LIGHTS
(REMOTE CONTROL TYPE)
I
Normal
1
Low oil
1 ON
OFF
1 OFF
OFF
ON
Overheat
/ zgi/
ON
1 OFF 1 ON
I -
Continuous
I
Continuous
/ Continuous I
63
6. OPERATION
(MOTOR PROTECTION
SYSTEM)
When the oil pressure warning sys- tems is activated:
1. Stop the engine immediately and check the engine oil level (refer to
2.If the oil is up to the recommended level, restart the engine. If the oil pressure warning system stops after
30 seconds, the system is normal.
If the throttle was closed suddenly after cruising at full throttle, the engine speed may drop below the specified idle speed.
This could cause the oil pressure warning system to activate momentarily.
3. If the oil pressure warning system stays activated after 30 seconds, return to the closest boat landing and contact your closest authorized
Honda Marine dealer.
COOLING SYSTEM INDICATOR
When the overheat warning system is activated:
1. Return the gearshift lever or control lever to the N (neutral) position immediately. Check to see if water is flowing out of the cooling system indicator.
2. If water is flowing out of the cool- ing system indicator, continue idling for 30 seconds. If the over- heat warning system stops after 30 seconds the system is normal.
If the motor is turned off after running at full throttle, the engine temperature may rise above normal. If the motor is restarted, shortly after being turned off, the overheat warning system could be activated momentarily.
3. If the overheat warning system stays activated, stop the engine. tilt up the motor and check the water intakes for obstructions. If there are no obstructions at the water intakes, return to the closest boat landing and contact your closest authorized
Honda Marine dealer.
64
.
.
,
Over-Rev Limiter
This outboard motor is equipped with an engine over-rev limiter which acti- vates when the engine speed increases excessively. The over-rev Iimiter can be activated while cruising, tilting up the motor, or when ventilation occurs during a sharp turn.
When the over-rev limiter is activated:
1 .Reduce the throttle opening immedi- ately and check the trim angle.
2.If the trim angle is correct but the oirer-rev limiter stays activated, stop the engine and check the con- dition of the outboard motor and check the propeller for damage.
Correct or service as necessary,.
6. OPERATION (MOTOR PROTECTION SYSTEM)
Power Trim Warning System
If the motor trim angle is more than
20’ and the control lever is moved more than 40’ forward/rearward from the N (neutral) position, an intermit- tent buzzer will sound and beep at one second intervals.
65
6. OPERATION (MOTOR PROTECTION SYSTEM)
Anodes
When the power trim warning system is activated:
1. Immediately decrease the trim angle by pressing the DN portion of the power trim/tilt switch.
2. Immediately reduce the throttle opening to SLOW and operate the engine at low speed.
The anodes are a sacrificial material which helps to protect the outboard motor from corrosion.
[ NQTICE] Painting or coating the anodes will lead to rust and corrosion damage to the outboard motor.
There are also 2 small sacrificial anodes in the water passages of the engine block.
66
ANODE(stern bracket)
.
,
.
Shallow Water Operation
INOTlCElExcessive trim/tilt angle during operation can cause the pro- peller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump and overheat the engine.
When operating in shallow water, tilt the motor up to prevent the propeller and gear case from hitting the bottom
(refer
motor tilted up, operate the motor at low speed.
Monitor the cooling system indicator for water discharge. Be sure that the motor is not tilted so high that the water intakes are out of the water.
If an excessive amount of throttle is used when operating in forward gear, the motor will return to the transom angle adjusting rod.
(Gas assisted tilt type).
If the motor trim angle is more than
20’ and the control lever is moved more than 40’ forward/rearward from the N (neutral) position, the power trim warning system will be activated
(Power trim/tilt type).
6. OPERATION
6’7
6. OPERATION
High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel con- sumption will increase. A very rich mixture will also foul the spark plugs and cause hard starting.
High altitude performance can be improved by specific modifi- cations to the carburetors. If you always operate your outboard at altitudes above 5,000 feet (1,524 meters) have an authorized
Honda Marine dealer perform this carburetor modification.
Even with carburetor modification, engine horsepower will decrease about 3.5% for each 1,000 foot (300 meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.
NOTICE
When the carburetors have been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 5,000 feet
(1,524 meters) with modified carburetors may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have an authorized Honda Marine dealer return the carburetors to original factory specifica- tions.
68
Emergency Engitie Stop
7. STOPPING THE ENGINE (TILLER HANDLE TYPE)
Normal Engine Stop
GEARSHIFT LEVER
.
.
LSWITCH CLIP
Disengage the emergency stop switch clip from the engine stop switch by pulling the emergency stop switch Ian- yard.
It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be sure that the switch is operating properly.
THROTTLE GRIP
1. Turn the throttle grip to SLOW position and move the gearshift lev- er to N(neutra1).
69
7. STOPPING THE ENGINE (TILLER HANDLE TYPE)
2. Push the engine stop switch until the engine stops.
70
7. STOPPING THE ENGINE (REMOTE CONTROL TYPE)
Emergency Engine Stop
EMERGENCY
STOP SWITCH
ERGENCY STOP
ITCH LANYARD
Normal Engine Stop
N Ineutral)
.
IGNITION KE
EMERGENCY STOP SWITCH CLIP
Disengage the emergency stop switch clip from the emergency engine stop switch by pulling the emergency stop switch lanyard.
It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be sure that the switch is operating properly.
1. Move the control lever to the N
(neutral) position and turn the igni- tion key to the OFF position.
2. When the boat is not in use, remove and store the ignition key.
71
8. TRANSPORTING
Trailering
STEERING FRICTION
If there is insufficient road clearance with the motor in the normal run po- sition, then trailer the motor in the tilted position using a motor support bar (refer to your motor support bar manufacturer’s instructions) or re- move the motor from the boat.
Close the fuel cap vent knob (refer
Disconnect the fuel coupling from the outboard motor (refer to page
When trailering or transporting the boat with the motor attached, it is recommended that the motor remain in the normal run position. Tighten the steering friction adjuster se- curely to stop the motor’s side to side movement.
Horizontal Transport
CASE PROTECTORS
Before removing the motor from the boat, drain the carburetors. Follow the
carburetor drain procedure on page 96.
Always rest the motor on the case protectors and be sure to protect it from impact and damage.
72
9. CLEANING AND FLUSHING
WA/SH PLUG (flush
plug)
Thoroughly clean and flush the out- board motor with fresh water after operating in dirty or salty water.
Flush Kit (optional part)
1. Wash the outside of the outboard motor with clean, fresh water.
2. Remove the wash plug and sealing washer from the WASH plug hole in the gear case. Be sure not to remove the oil level plug from the
OIL LEVEL plug hole in the gear case.
FLUSH KI’I’ COUPLER
I
B Keep children and pets away from the area, and stay clear of all moving parts during this procedure.
3. Remove the sealing washer from the wash plug and install the sealing washer on the flush kit coupler.
4. Install the flush kit coupler into the
WASH plug hole and connect a fresh water hose to the flush kit coupler.
5. Move the gearshift lever or control lever to the N (neutral) position.
Flush the outboard motor in the neutral position only.
6. Turn on the fresh water supply to the flush kit coupler.
-1 Running the outboard motor without suffkient cooling water will damage the water pump and overheat the engine.
73
9. CLEANING AND FLUSHING
CdOLINi; SYSTEM
INDICATOR
7. Start the engine. Monitor the cool- ing system indicator. Stop the engine if water does not come out of the cooling system indicator and check the fresh water supply. If the fresh water supply is insufficient it may be necessary to temporarily cover the three water intakes with duct tape.
74
8. Allow the engine to run at idle for at least 5 minutes to clean the inside of the motor.
9. Stop the motor and remove the flush kit coupler. lO.Remove the sealing washer from the flush kit coupler and install the sealing washer on the wash plug.
If tape was used to cover the three water intakes in step 7, remove the tape now.
11 .Install the wash plug into the gear case securely.
;
;
I
.
THE IMPORTANCE OF
MAINTENANCE
Good maintenance is essential for safe, economical, and trouble-free operation.
It will also help reduce pollution.
m Improper mainte- nance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.
Always follow the inspection and maintenance recommen- dations and schedules in this owner’s manual.
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
10. MAINTENANCE
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 techni- cian or other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If you operate your outboard motor under unusual conditions, consult your servic- ing dealer for recommendations applica- ble to your individual needs and use.
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.
MAINTENANCE SAFETY
Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing mainte- nance. Only you can decide whether or not you should perform a given task.
m Failure to properly follow maintenance instruc- tions and precautions can cause you to be seriously hurt or killed.
Always follow the procedures and precautions in this own- er’s manual.
75
10. MAINTENANCE
Safety Precautions
l
Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:
-Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventila- tion whenever you operate the engine.
- Bums from hot parts.
Let the engine cool before touch- ing.
-Injury from moving parts.
Do not run the engine unless instructed to do so. l
Read the instructions before you begin, and make sure you have the tools and skills required. l
To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflam- mable solvent, not gasoline to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.
Remember that an authorized Honda
Marine dealer knows your outboard motor best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new, genuine
Honda parts or their equivalents for repair and replacement.
EMISSION CONTROL SYSTEM
INFORMATION
Source of Emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocar- bons and oxides of nitrogen is very important because, under certain conditions, they react to form photo- chemical smog when subjected to sunlight.
Honda utilizes lean carburetor settings and other systems to reduce the emis- sions of oxides of nitrogen and hydro- carbons.
76
6
; i
The U.S. Clean Air Acts
EPA regulations require all manufactur- ers to furnish written instructions describing the operation and mainte- nance of emission control systems.
The following instructions and proce- dures 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: l
Removal or alteration of any part of the intake, fuel, or exhaust systems. l
Alterations that would cause the engine to operate outside its design parameters.
.
10. MAlNTENANCE;
Problems That May Affect Emis- sions
If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. l
Hard starting or stalling after starting. l
Rough idle. l
Misfiring or backfiring under load. l
Afterbuming (backfiring). l
Black exhaust smoke or high fuel consumption.
77
10. MAINTENANCE
Replacement Parts
The emission control systems on your
Honda engine were designed, built, and certified to conform with EPA emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done.
These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.
The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emis- sion 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.
78
Maintenance
Follow the maintenance schedule on
page 80. Remember that this schedule is
based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high- temperature operation, or use in unusu- ally wet or dusty conditions, will require more frequent service.
.
10. MAINTENANCE
Tool Kit and Spare Parts
The following tools and spare parts are supplied with the outboard motor for maintenance, adjustment, and emergency repairs.
TOOL KIT
10 x 12 mm WRENCH
8 mm WRENCH
1
FLAT SCREWDRIVER
PHILLIPS SCREWDRIVER
OIL CHECK SCREWDRIVER
PLIERS
C
0
2
SCREWDRIVER HANDLE
TOOL BAG
18xl9mm
SOCKET
WRENCH
79
10. MAINTENANCE
MAINTENANCE SCHEDULE
Use only genuine HONDA parts or their equivalent for maintenance or repair.
Replacement
parts
which are not of equivalent quality may damage the motor.
0 Engine oil
Gear
case oil
Check level
Change
EACH USE
FIRST
20 HRS
OR MONTH
0
0
0
EVERY
100 HRS OR
6 MONTHS
EVERY
200 HRS
OR YEARLY
EVERY
400 HRS OR
2 YEARS
0
0
0
I
m) I
O(2)
00)
Timing Belt
Carburetor linkage
Change
Check-readjust
Check
Idling
D I Valve clearance
Adjust
Check-readjust
B Spark plugs Check-clean(Replace if necessary)
I
Propeller and cotter pin Check
(Replace if necessary)
Grease i0
Lubrication
0
O(2)
0
O(l)
O(2)
O(2)
O(2)
O(I)
O(2)
0
I
10. MAINTENANCE
REGULAR SERVICE PERIOD (3)
Perform at every indicated month or operating hour intervals, whichever comes first.
ITEM
Fuel tank and filter
Clean
Fuel filter filter
(Replace if necessary)
Check
D Fuel line
Change
Check
Check
1
Battery cable
Bolts and Nuts
0 Emission-related items
(Replace if necessary)
Check-tightness
Check-tightness
EACH USE
0
FIRST
20 HRS
OR MONTH
0
O(2)
(1) Lubricate more frequently when used in salt water.
(2) These items should be serviced by an authorized Honda Marine dealer, unless the owner has the proper tools and is mechanically proficient. See the Honda
Shop Manual.
(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.
EVERY
100 HRS OR
6 MONTHS
0
0
O(2)
EVERY
200 HRS
OR YEARLY
0
0
O(2)
EVERY
400 HRS OR
2 YEARS
0
O(2)
81
10. MAINTENANCE
Engine Oil
Engine oil is a major factor affecting engine performance and service life.
Oil check interval:
Each use.
Oil change interval:
After the first 20 hours, then every
100 hours. (Refer to the maintenance
OIL CAPACITY:
2.1 US qt (2.0 lit)...When oil filter is not replaced
2.5 US qt (2.4 lit)....When oil filter is replaced
Recommended oil:
BF40Al50A...SAE5W-30 engine oil,
API Service classification Fuel Efficient
SG, SH.
OILF
CAP
Engine Oil Replacement
Drain the oil while the engine is still warm to assure rapid and complete draining.
1. Position the outboard motor verti- cally, and remove the engine cover.
Remove the oil filler cap.
82
10. MAINTENANCE
DRAIN PLUG
DRAIN PLUG
2. Loosen the drain plug cover screw using a flat blade screwdriver and remove the drain plug cover.
3. Place the drain plug cover as shown to use it as an oil drain guide. Place a suitable container under the guide.
4. Remove the engine oil drain bolt and washer using a 12 mm wrench and drain the engine oil.
5. Install a new sealing washer on the drain bolt and tighten the bolt securely.
6. Reinstall the drain plug cover.
83
10. MAINTENANCE
7. Refill to the upper limit mark on the oil level dipstick with the recom- mended oil.
NOTE: To avoid incorrect gauging of the engine oil level, inspect the oil level when the engine has cooled. The outboard motor needs to be in the vertical position.
8. Reinstall the oil filler cap.
Always wash your hands after handling used oil.
Also, please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station reclamation center. Do not throw it in the trash, pour it on the ground, down a drain, or into the water.
Gear Oil
Oil check interval:
Every 100 hours.
Oil change interval:
After the first 20 hours, then every
100 hours. (Refer to the maintenance
OIL CAPACITY:
0.53 US qt. (0.5 lit)
Recommended oil:
Outboard motor SAE 90 hypoid gear oil API Service Classification
(GL-4 or GL-5).
10. MAINTENANCE
LEVEL PLUG
DRAIN PLUG
Gear Oil Level/Check
1. Position the outboard motor verti- cally.
2. Remove the level plug and see if oil flows out. If no oil flows out, fill through the drain plug hole until the oil starts to flow out through the level plug hole. If there is water in rhe oil, the water will flow out first when the drain plug is removed, or the oil will be milky colored. If the oil appears abnormal contact your closest authorized Honda Marine dealer.
GEAR OIL BOTI’LE
A gear oil bottle is recommended to fill the gear case.
The end of the drain plug is a mag- net. Remove all metal particles from the end of the drain plug before reinstalling. Do not reinstall the drain plug in the level plug hole.
3. Use new sealing washers and rein- stall the level plug and drain plug securely.
Gear Oil Change
1. Position the outboard motor verti- cally.
2. Remove the level plug and drain plug to drain the oil. Inject oil through the drain plug hole until it starts flowing out through the level plug hole. Use new sealing washers and reinstall the level plug first and then the drain plug securely.
OIL
CAPACITY:
0.53 US qt. (0.5 lit)
10. MAINTENANCE
Spark Plugs
To ensure proper engine operation, the spark plugs must be properly gapped and free of deposits.
Check-replace interval:
After the first 20 hours, then every
200 hours. (Refer to the maintenance
Recommended spark plug:
DR7EA (NGK),
X22ESR-U (DENSO)
Use only the recommended spark plugs or equivalent.
m Spark plugs which have an improper heat range may cause engine damage.
I. Allow the engine to cool. The spark plugs will be hot if the engine has been running.
2. Remove the engine cover.
3. Disconnect the spark plug caps from the spark plugs.
4. Use the wrench and screwdriver supplied in the tool kit to remove the spark plugs.
5. Check the spark plugs. Replace the spark plugs if there is apparent wear, or if the insulators are cracked or chipped. Clean the spark
*plugs with a wire brush if they are to be reused.
6. Measure the plug gaps with a spark plug gap gauge.
The gaps should be 0.024-0.028 in
(0.6-0.7 mm). Correct as necessary by carefully bending the side elec- trode.
86
7. Thread the plugs in by hand to pre- vent cross threading.
8. After the spark plugs are seated, tighten with a spark plug wrench to compress the washers.
If installing new spark plugs, tighten l/2 turn after the spark plugs seat to com- press the washers. if reinstalling used spark plugs, tighten I /8- 114 turn after the spark plugs seat to compress the washers.
@&@I The spark plugs must be securely tightened. A loose spark plug can become very hot and may cause engine damage.
Overtightening the spark plugs can damage the threads.
10. MAINTENANCE
Battery (not included)
Minimum requirements
12V-7OA.H marine cranking battery.
87
10. MAINTENANCE
To protect the battery from mechani- cal damage and to prevent the bat- tery from falling or tipping over, the battery must be: l l l l
Installed in the correct size corro- sion-resistant battery box.
Properly secured in the boat.
Secured in a location free from di- rect sunlight and water spray.
Secured away from the fuel tank to avoid potential sparks near the fuel tank.
1. Install the battery in the battery box.
2. Connect the positive (+) battery cable first, then connect the nega- tive (-) battery cable. Tighten the cable nuts securely.
3. Coat the battery terminals and ca- ble ends with marine anticor- rosion grease.
4. Put the cover on the battery box and secure the battery box to the boat.
Lubrication
Lubrication interval: After the first 20 hours, then every 100 hours.
(Refer to the maintenance schedule page’80.)
Apply marine anticorrosion grease to the following parts:
,- THROTTLE REEL -,
- PROPELLER SHAFT -
TILT SHAFT
88
.
3
10. MAINTENANCE
Engine Fuel Filter
FU
FUEL FILTER
The engine fuel filter is located under the engine cover between the fuel cou- pling and the fuel pump. Water or sediment accumulated in the fuel filter can cause loss of power or hard start- ing.
Check interval:
Every 100 hours (Refer to the mainte-
Change interval:
Every 400 hours (Refer to the mainte-
CONNECTOR
B Gasoline is extremely flammable, and gaso- line vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP
OUT OF REACH OF CHILDREN.
Always work in a well-ventilated area.
Make sure that any fuel drained from the outboard motor is stored in an approved gasoline container. Be careful not to spill any fuel when replacing the filter.
Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.
CHOKE KNOB
Check
1. Disconnect the fuel hose connector from the outboard motor.
2. Pull the choke knob fully and remove the engine cover.
89
10. MAINTENANCE
FUEL HOSES
SPRINti
RETAINER
F”ELF2FQ
3. Pull the spring retainer toward you, and raise the fuel filter.
4. Check the fuel filter for water accu- mulation or sediment. If no water or sediment are found, reinstall the fuel filter properly.
Change
1. Remove the fuel filter.
Before removing the fuel filter, to prevent fuel leakage, place fuel hose clamps on the fuel hoses at each side of the fuel filter.
ARROW (Fuel Flow Direction)
2. Install the new fuel filter so the arrow on the fuel filter points toward the fuel pump.
Fuel flow will be reduced if the fuel filter is installed backward.
3. Connect the fuel hoses to the fuel filter securely with the hose clips.
Remove the fuel hose clamps used to close the fuel hoses.
.
.
4. Securely connect the fuel hose connector to the outboard motor(refer
5. Prime the engine using the primer
bilb (refer to page 36). Check for fuel
leaks.
Repair any fuel leaks if necessary.
If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.
Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.
Fuel Tank and Filter
Cleaning interval:
/
FUEL
HOSE
Every
200 hours (Refer to the
maintenance schedule page 81).
Inspect the condition of the fuel cap gasket, fuel hose, and the O-ring seals in the fuel hose connectors. Replace the fuel cap gasket, hose, or fuel con- nectors if they are cracked, damaged or leak fuel. Be sure the fuel hose is not kinked.
10. MAINTENANCE
Fuel Tank Cleaning
1. Disconnect the fuel hose from the fuel tank.
B Gasoline is extremely flammable, and gaso- line vapor cati explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP
OUT OF REACH OF CHILDREN.
2. Empty the gasoline from the fuel tank into an approved gasoline con- tainer. Pour in a small quantity of fresh gasoline, and clean the tank thoroughly. Drain and dispose of the gasoline properly.
91
10. MAINTENANCE
FUEL TANK HOSE
CONNECTOR
Fuse Replacement
FUSE COVER
J
- FUEL TANK
FILTER
Fuel Tank Filter
Cleaning/Replacement
1. Turn the fuel tank hose connector counterclockwise to remove the fuel tank filter.
2. Clean the fuel tank filter with non- flammable cleaner or solvent.
Replace the fuel tank filter if neces- sary.
3. After cleaning or replacement, rein- stall the fuel tank filter and fuel tank hose connector securely.
BLOWN FUSE
If the fuse is blown, running the engine will not charge the battery and the electric starter will not work.
FUSE RATING: 15A
Never use a fuse with a different rat- ing from that specified.
If the fuse is blown, check the cause, then replace the fuse with a spare fuse of the same rated capacity. Unless the cause is found, the fuse may blow again.
92
Replacement
1. Stop the engine.
2. Remove the engine cover.
3. Pull the blown fuse out of the clip.
4.
Push a new 15A fuse into the clip.
A spare 15A fuse is located in the fuse holder. If the spare fuse is not available, the motor will need to be started with the pull starter rope (refer to the emergency
.
10. MAINTENANCE
Propeller
COTTER PIN (stainless)
\ \
.
SPECIAL SPLINE WASHER
THRUST WASHER
MARINE GREASE
4h
If the propeller is damaged, replace it as follows:
Removal:
Remove the cotter pin then remove the
16 mm castle nut, 17 mm plain washer, 10 mm special spline washer, propeller and thrust washer.
COTTER PIN
(stainless)
Installation:
Install the thrust washer with the grooved side toward the gear case. then install the new propeller in the reverse sequence of removal.
Hand tighten the castle nut until the 4 mm cotter pin can be installed. If necessary, tighten the castle nut just enough to align the hole with the groove in the nut.
Use a new genuine Honda cotter pin and bend the cotter pin ends as shown.
93
10. MAINTENANCE
Submerged Motor
A submerged motor must be serv- iced immediately after it is recov- ered from the water inorder to mimumize corrosion.
Immediately take the outboard mo- tor to the closest authorized Honda
Marine dealer or if you are far from a dealership, proceed as follows:
1. Remove the engine cover, and rinse the motor with fresh water to remove salt water, sand, mud. etc.
2. Dram the carburetors (Refer to
3. Disengage the emergency stop switch clip from the emergency stop switch.
4. Remove the spark plugs.
EMERGENCY STARTER ROPE
5. Remove the flywheel cover fol- lowing the emergency starting
procedure (refer to page 44) and
remove the water from the cylin- ders by pulling the emergency starter rope several times. If the motor was running when it sub- merged, there may be mechanical damage, such as bent connecting rods. If the engine binds when ro- tated with the emergency starter rope, do not proceed or attempt to run the motor until it has been repaired.
6. Change the engine oil (refer to page
7. Put a teaspoon of engine oil into each spark plug hole to lubricate the inside of the cylinders. Then rotate the engine several times, us- ing the emergency starter rope.
Reinstall the spark plugs.
(NoTICE] Running the outboard motor without suffkient cooling water will damage the water pump and overhetit the engine.
94
.
.
8. Engage the emergency stop switch clip with the emergency stop switch and attempt to start the engine (be sure the water level is at least 2 inches above the anti-ventilation plate). l l
If the engine fails to start, re- move the spark plugs, clean and dry the electrodes, then re- install the spark plugs and at- tempt to start the engine again.
If the engine starts, and no me- chanical damage is evident, continue run the engine for a l/2 hour or longer. l
If there was water in the en- gine crankcase, or the used en- gine oil showed signs of water contamination, then a second engine oil change should be performed after running the en- gine for a II2 hour.
9. Take the outboard motor to your closest authorized Honda Marine dealer for inspection and service as soon as possible.
10. MAINTENANCE
95
11. STORAGE
For longer service life of the outboard motor;have your outboard motor ser- viced by an authorized Honda Marine dealer before storage.
If you are unable to take the motor to your dealer, proceed as follows:
Draining the Carburetors
Be careful not to spill gasoline. Spilled gasoline or gasoline vapor may ignite.
If any gasoline is spilled, make sure the area is dry before storing or trans- porting the motor. Do not smoke or allow flames or sparks where gasoline is drained or stored.
B Gasoline is extremely flammable, and gaso- line vapor, can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT
OF REACH OF CHILDREN.
DRAIi SCREW
1. Disconnect the fuel hose connector.
2. Pull the #3 carburetor drain hose outside of the motor pan.
3. Loosen the drain screw of the #3 carburetor and drain the carburetor.
Catch the draining gasoline in an approved gasoline container.
4. Drain the #l and #2 carburetors in the same manner using the #3 car- buretor drain hose.
96
#2 CARBURETOR
#l CARBURETOR
#3CARBURETOR
DRAIN SCREW
5. After thoroughly draining the car- buretors, tighten the drain screws securely.
6. Reinstall the drain hose back on the
#3 carburetor.
11. STORAGE
Fuel Tank
VENT KNOB
Outboard Motor Position
FUEL CAP
1. Close the fuel cap vent knob.
2. Disconnect the fuel coupling from the outboard motor (refer to
Transport and store the motor either vertically or horizontally, as shown above. Store the outboard motor in a well-ventilated area free from direct sunlight and humidity.
Vertical transport or storage:
Attach the stern bracket to stand.
CASE PROTECTORS
Horizontal transport or storage:
Rest the motor on the case protectors.
NOTICE
1 Improper transport or storege can damage the motor or cause oil leakage.
97
12. TROUBLESHOOTING
(1) Engine does not start.
Fuel l
Fuel is not fed to carburetor.
There is no gasoline in fuel tank.
Vent knob is not open or vent clogged.
Fuel filter is clogged.
Fuel line is kinked.
Fuel line is connected improper1 y.
Fuel pump is faulty.
Primer bulb is faulty.
Check valve in connector is faulty
Electrical l
Sparks across sparlcplug gap clogged.
Insufficient - Spark plug gap is small. sparks Weak starter motor
Normal - sparks rotation.
Recheck the fuel system. l
No sparks - across spark plug gap
- Spark plug is faulty.
P
Contamination
Incorrect gap
Broken spark plug
-Wire
-
Pulser coil is faulty.
Current leaks from high tension cord.
i!!F
Ignition coil is faulty. harness is faulty.
-
Current leaks from engine stop switch cord.
-
1 Stop switch does not return
L
satisfactorily.
Spark plug is improperly installed.
Emergency stop switch is improperly installed.
Shift lever is not in v position. t
.
+
12. TROUBLESHOOTING
(2) Engine starts but immediately stops. Engine some
times stops while cruising.
Fuel
l
No gasoline in fuel tank. l
The&2 is gasoline - in fuel tank.
Water is mixed with gasoline.
Vent knob is not open or vent is clogged.
Fuel filter is clogged.
-
-
-
I
Air screw is open too wide.
Idling speed is too slow.
Carburetor vent is clogged.
Fuel pump is faulty.
Air in fuel pump.
Air enters through fuel line connector.
Aii enters through primer bulb.
Engine overheats
. Normal sparking l-l
-
-
Water intake screens are clogged.
Spark plug is not of speci- fied rating.
Water pump is faulty.
Thermostat is clogged.
Thermostat is faulty.
Water tube or passage is clogged.
Exhaust gas is entering cooling system.
99
13. SPECIFICATIONS
MODEL
Description
Type
Code
Overall length
Overall width
Overall height
Transom height
X
L
L
BF40A
Long shaft: BAYL
Extra long shaft: BAYU
H
28.6 in
(725 mm)
R
27.0 in
(685 mm)
14.6 in (370 mm)
RT
27.0 in
(685 mm)
53.6 in (I ,360 mm)
57.5 in (I ,460 mm)
20.5 in (520 mm) x 24.5 in (622 mm)
Weight
Rated power
Full throttle range
Engine type
Displacement
Spark plug gap
L 201 lb (9 I kg) 198 lb (90 kg) 203 lb (92 kg
X
212Ib(96kg
40 HP (29.8 kW)
5,000 - 6,000 rpm
4 stroke OHC in-line 3 cylinder
49.3 cu. in (808 cc)
0.024 - 0.028 in (0.6 - 0.7 mm)
100
Starter system
Ignition system
Lubrication system
Specified oil
Oil capacity
DC. output
I
Electric starter
CD.1
Trochoid pump pressure lubrication
Engine:
API standard
(Fuel Efficient SG, SH) SAE
SW-30
Gear case: API standard (GL-4/5)
SAE 90 outboard motor gear oil
Engine: 2.5 US qt (2.4 lit.)
Gear case: 0.53 US qt (0.5 lit.) l2V-IOA
Fuel pump
Fuel
Tank capacity
Gear change
Steering angle
Transom angle
Diaphragm type
Automotive gasoline (86 pump octane)
6.6 US gal. (25 lit.)
Forward-Neutral-Reverse
37.5’ right and left
(dog type)
5 stages
(I 1.5’. 15.5’. 19.5”. 23.5’. 27.5’)
MODEL
Description Code
Type
Overall length
Overall width
Overall height
Transom height
L
X
L
Weight
X
L
X
Rated power
Full throttle range
Engine type
Disolacement
Spark plug gap
BFSOA
Long shaft: BAZL
Extra Long shaft: BAZU
R
21.0 in
(685 mm)
RT
27.0 in
(685 mm)
14.6 in (370 mm)
53.6 in (I ,360 mm)
57.5 in (I ,460 mm)
20.5 in (520 mm)
24.5 in (622 mm)
198 lb (90 kg) 203 lb (92 kg)
212 Ib(96 kg)
50 HP (31.3 kW)
5,500 - 6,000 rpm
4 stroke OHC in-line 3 cylinder
49.3 cu. in (808 cc)
0.024 - 0.028 in (0.6 - 0.7 mm)
13. SPECIFICATIONS
Starter system
Ignition system
Lubrication system
Specified oil
Oil capacity
D.C. output
Cooling system
Exhaust system
Spark plugs
Fuel pump
Fuel
Tank capacity
Gear change
Steering angle
Transom angle
Electric starter
C.D.1
Trochoid pump pressure lubrication
Engine:
API standard
(Fuel Efficient SG, SH) SAE
5w-30
Gear case: API standard (CL-41.5)
SAE 90 outboard motor gear oil
Engine: 2.5 US qt (2.4 lit.)
Gear case: 0.53 US qt (0.5 lit.)
12V-IOA
Water cooling with thermostat
Thru-hub
DR7EA (NGK).
X22ESR-U (DENSO)
Diaphragm type
Automotive gasoline (86 pump octane)
6.6 US gal. (35 lit.)
Forward-Neutral-Reverse
37.5” riaht and left
(dog type)
5 stages
(I 1.5”. 15.5”. 19.5’. 23.5”. 27.5’)
I
101
14. WARRANTY SERVICE
Warranty Service Information
Servicing dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management.
The Service Manager of General
Manager can help. Almost all problems are solved in this way.
If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Marine Customer
Relations Office.
You can write:
American Honda Motor Co., Inc.
Marine Division
Customer Relations Office
4475 River Green Parkway Duluth,
Georgia 30136-2565
Or telephone: (770) 497-6400
When you write or call, please give us this information: l
Model and serial numbers (see page
l
Name of the dealer who sold the outboard motor to you l
Name and address of the dealer who services your outboard motor l
Date of purchase l
Your name, address, and telephone number l
A detailed description of the problem
102
Current customer service contact information:
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 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:
American Honda Motor Co., Inc.
Marine Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST
When you write or call, please provide the following information:
• Your name, address and telephone number (complete with area code)
• Model and complete serial number
• Date of purchase
• Name and location of the selling dealer
• Name and location of the servicing dealer (if different)
• A detailed description of your concerns
TILLER HANDLE TYPE
15. WIRING DIAGRAM
103
15. WIRING DIAGRAM
REMOTE CONTROL TYPE
L1
REMOTE CONTROL,
POWER TRIM/TILT
TYPE
r---------------’
XRTA type outboard
I
I
I
I r- n
I
I
I
I
‘7 -A
15. WIRING DIAGRAM
16. INDEX
Anode Metal ......................................................................
PRE-OPERATION CHECK ........................................
24
34
MOTOR PROTECTION SYSTEM ............................. 66
Battery (not included) ........................................................
Break-in Procedure ............................................................
Choke Knob .......................................................................
87
50
Choke/Fast Idle Lever ........................................................
CLEANING
COMPONENT
AND FLUSHING
IDENTIFICATION
........................................
...................................
11
18
73
8
CONTROLS & INSTRUMENTS (common) ...................
23
CONTROLS
GAS ASSISTED TILT TYPE .....................................
TILLER HANDLE TYPE ...........................................
REMOTE CONTROL TYPE ......................................
22
11
15
REMOTE CONTROL & POWER TRIM/TILT TYPE.. .. 20
Cooling System Indicator .................................................. 24
Cruising
TILLER HANDLE TYPE ...........................................
REMOTE CONTROL TYPE ......................................
Emergency Starting ...........................................................
52
54
44
Emergency Stop Switch Lanyard
TILLER HANDLE TYPE ........................................... 13
REMOTE CONTROL TYPE ......................................
Engine Cover Removal/Installation
...................................
Engine Fuel Filter ..............................................................
Engine
Oil
Level check .............................................................
Change ....................................................................
17
28
89
;;
106 Pressure and Overheat Warning System ................
63
16. INDEX
Over-Rev Limiter .........................................................
Start Button ..................................................................
Stop Switch ..................................................................
27
1 1
13
Fuel
Cap/Gauge/Vent/Knob
................................................. 27
Level ..............................................................................
Line Connection ...........................................................
Tank and Filter .............................................................
Tank and Vent Knob ....................................................
.30
35
91
35
Fuel Recommendations .....................................................
Fuse Replacement
..............................................................
3 1
92
Gear Oil ... . .............. . . . ............................. . .......................... 84
Gear Shifting
TILLER HANDLE TYPE ...........................................
REMOTE CONTROL TYPE ......................................
High Altitude Operation ....................................................
Ignition Switch ...................................................................
5 1
53
68
16
Lubrication .........................................................................
MAINTENANCE
..............................................................
88
75
EMISSION CONTROL SYSTEM INFORMATION
.. .76
MAINTENANCE SAFETY .........................................
.75
SCHEDULE .................................................................
77
THE IMPORTANCE OF MAINTENANCE
............... .75
Manual
Choke Knob
Relief Valve
.................................................................
18
CONTROLS ...........................................................
OPERATION .........................................................
MOTOR PROTECTION SYSTEM ..................................
Neutral Release Lever ........................................................
22
60
63
16
-r
*
‘I
-
:
a
.
. w
Oil Pressure Indicator Light.. .............................................
Oil Pressure Indicator Light/Buzzer
..................................
Other Checks .....................................................................
Over-Rev Limiter.. .............................................................
Overheat Indicator Light.. ..................................................
Overheat Indicator Light/Buzzer
.......................................
14
19
34
65
14
Oxygenated Fuels ..............................................................
Power Tilt Switch (Motor Pan)
I9
32
CONTROLS .................................................................
OPERATION ............................................................... z:,
Power Trim Warning System ............................................
Propeller .............................................................................
65
Power Trim Tilt Switch (remote control lever) .................
20
PRE-OPERATION CHECKS ...........................................
28
93
Cotter Pin .....................................................................
Remote Control
33
Friction Adjustment
.....................................................
Lever ............................................................................
34
15
SAFETY ..............................................................................
INFORMATION
............................................................
6
7
LABELS .........................................................................
Shallow Water Operation
..................................................
Shift Lever .........................................................................
6
67
11
Spark Plug ..........................................................................
86
SPECIFICATIONS
..........................................................
STARTING THE ENGINE
100
REMOTE CONTROL TYPE ......................................
4 1
TILLER HANDLE TYPE ...........................................
37
16. INDEX
Steering ..............................................................................
Friction Adjustment (common) ....................................
Stern bracket
PRE-OPERATION
CHECK ........................................
STOPPING THE ENGINE
REMOTE CONTROL TYPE ......................................
TILLER HANDLE TYPE ...........................................
STORAGE .........................................................................
Submerged Motor ..............................................................
Tachometer ........................................................................
Throttle
Friction Knob ...............................................................
Grip ................................................................................
Opening Indicator ........................................................
Tilt Lever ...........................................................................
Tilt Lock Lever
CONTROLS .................................................................
OPERATION
...............................................................
Tilting motor
GAS ASSISTED TILT TYPE .....................................
POWER TRIM/TILT TYPE ........................................
Tool Kit.. ............................................................................
Tool Kit and Spare Parts ....................................................
Transom Angle Adjusting Rod ..........................................
TRANSPORTING .............................................................
Trim Meter
Controls ........................................................................
Operation ......................................................................
Trim Tab ............................................................................
52
33
34
7 1
69
96
ST
12
12
12
22
::
55
58
34
76
26
72
21
59
23
107
16. INDEX
Trim Tab Adjustment ........................................................
TROUBLESHOOTING ....................................................
62
98
Starting Problems .........................................................
49
WARRANTY SERVICE ................................................. 102
Water Intakes .....................................................................
25
WIRING DIAGRAM ........................................................ 103
108
I
31 ZW4602
O~X3l -ZW4-6020 111
I Y P~WFtH OF
SERVICE
COMMUNICATIONS
DO NOT REMOVE
__ _.
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PoM52825-cVR
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advertisement
Key Features
- 40 horsepower engine
- Fuel-injected engine
- Maintenance-free battery
- Power Trim/Tilt
- Remote control operation
- Emergency stop switch lanyard
- Oil pressure indicator light
- Overheat indicator light
- Trimmeter
- Tachometer