Honda BF4A, BF5D, BF6A Operation And Maintenance Ma

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Thank you for purchasing a Honda

Outboard Motor.

This manual covers operation and maintenance of the Honda BF4A/

BF5D/BF6A Outboard Motors.

All information in this publication is based on the latest product information available at the time of approval for 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 should remain with it if it is resold.

Throughout this manual, you will see safety messages proceeded by the following words and symbols. Here’s what they mean:

If a problem should arise, or if you have any questions about the

Outboard Motor, consult an authorized Honda Outboard Motor dealer.

Indicates serious injury or death

WILL result if instructions are not followed.

Indicates a strong possibility that serious personal injury or death may result if instructions are not followed.

Indicates a possibility that personal injury or equipment damage could result if instructions are not followed.

Indicates that equipment or property damage could result if instructions are not followed.

Gives helpful information.

Honda Outboard Motors are designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the Outboard

Motor. Failure to do so could result in personal injury or equipment damage.

• The illustration may vary according to the type.

Honda Motor Co., Ltd. 2016, All

Rights Reserved

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Model

Type

Shaft Length

Fuel Tank

Charging System

S

L

Internal fuel tank

Portable fuel tank

BF4A

SHND

SHNU

●

LHND

LHNU

●

●

●

* *

SHND

SHNU

●

●

*

*

SHD

SHU

●

BF5D

LHND

LHNU

●

*

●

*

*

●

●

LHD

LHU

*

●

●

●

SHND

SHNU

●

●

*

*

SHD

SHU

●

BF6A

LHND

LHNU

●

*

●

*

*

●

●

LHD

LHU

*

●

●

●

*: Optional equipment

Note that the types of the outboard motor differ according to the countries where they are sold.

BF4A/BF5D/BF6A are provided with the following types according to the shaft length, control system, and charging system.

• According to Shaft Length

S: Short Shaft

L: Long Shaft

• According to Control System

H: Tiller Handle Type

• According to Charging System

N: Without System

TYPE CODE (Example)

S H N U

Destination

U=Europe

D=General export

Charging System

N=Without System

Throttle type

H: Tiller Handle Type

Shaft Length

S=Short Shaft

L=Long Shaft

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Check the type of your outboard motor and read this Owner’s Manual thoroughly before operation.

Texts with no type indication are the information and/or procedures common to all types.

ENGINE SERIAL NUMBER

FRAME SERIAL

NUMBER

The frame serial number is stamped on a plate attached on the left side of the stern bracket.

The engine serial number is located on the cylinder block.

Frame serial number:

Engine serial number:

Record the frame and engine serial numbers for your reference. Refer to the serial numbers when ordering parts, and when making technical or warranty inquiries.

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CONTENTS

1. SAFETY ...................................................................... 6

SAFETY INFORMATION ....................................... 6

2. SAFETY LABEL LOCATIONS ................................ 9

CE mark location ..................................................... 11

3. COMPONENT IDENTIFICATION ......................... 12

4. CONTROLS .............................................................. 14

Starter Grip .............................................................. 14

Shift Lever ............................................................... 14

Fuel Valve Lever ..................................................... 15

Handle Stopper ........................................................ 16

Choke Knob ............................................................. 17

Throttle Grip ............................................................ 17

Throttle Friction Knob ............................................ 17

Fuel Primer Bulb ..................................................... 18

Emergency Stop Switch .......................................... 18

Emergency Stop Switch Lanyard/Clip .................... 18

Oil Pressure Indicator Light .................................... 19

Tilt Lever ................................................................. 20

Anode Metal ............................................................ 20

Cooling Water Check Hole ..................................... 20

Cooling Water Intake Port ....................................... 21

Engine Cover Latch ................................................. 21

Steering Friction Bolt .............................................. 21

Transom Angle Adjusting Rod ............................... 22

Fuel Filler Cap Vent Knob/Fuel Gauge .................. 22

Fuel Filler Cap Vent Knob ...................................... 23

Clamp Screws .......................................................... 23

4

Fuel Inlet Cap and Fuel Inlet (BF5D and BF6A) ....23

Fuel Line Connector ................................................24

5. INSTALLATION ......................................................25

Transom Height .......................................................25

Location ...................................................................25

Installation Height ...................................................26

Outboard Motor Attachment ....................................27

Outboard Motor Angle (Cruising) ...........................27

Battery Connections .................................................29

Battery Charge Cable ...............................................30

6. PRE-OPERATION CHECKS ...................................31

Removing Engine Cover ..........................................31

Installing Engine Cover ...........................................31

Engine Oil Level ......................................................32

Fuel Level ................................................................34

Gasoline Containing Alcohol ..............................36

Battery Electrolyte Level .........................................37

Other Checks ...........................................................38

7. STARTING THE ENGINE .......................................39

Priming the Carburetor with Gasoline .....................39

Fuel Tank and Vent Knob ........................................40

Fuel Line Connection ..............................................41

Starting the Engine ..................................................43

Emergency Starting .................................................48

Troubleshooting Starting Problems .........................53

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8. OPERATION ............................................................ 54

Break-in Procedure .................................................. 54

Gear Shifting ........................................................... 54

Steering .................................................................... 55

Cruising ................................................................... 56

Tilting the Outboard Motor ..................................... 57

Cruising in Shallows ............................................... 60

High Altitude Operation .......................................... 60

9. STOPPING THE ENGINE ....................................... 61

Stopping the Engine ................................................ 61

10. TRANSPORTING ................................................... 63

Fuel Line Removal (Optional equipment for BF5D and

BF6A) ................................................................... 63

Transporting ............................................................ 64

Trailering ................................................................. 67

11. CLEANING AND FLUSHING .............................. 68

With Water Hose Joint (Optional equipment) ......... 68

Without Water Hose Joint ....................................... 69

12. MAINTENANCE .................................................... 70

Tool Kit and Spare Parts ......................................... 71

MAINTENANCE SCHEDULE .............................. 72

Engine Oil Change .................................................. 74

Gear Oil Change ...................................................... 76

Starter Rope Check .................................................. 77

Spark Plug Service .................................................. 78

Battery Service ........................................................ 80

Lubrication .............................................................. 82

CONTENTS

Fuel Filter Check/Replacement ...............................83

Fuel Tank Cleaning and Tank Filter Cleaning ........85

Replacing the Fuse ...................................................86

Propeller and Shear Pin Change ..............................87

Servicing a Submerged Outboard Motor .................88

13. STORAGE ...............................................................90

Fuel ..........................................................................90

Draining the Gasoline ..............................................90

Outboard Motor Storage ..........................................91

Battery Storage ........................................................92

Storage Position of the Outboard Motor ..................94

14. DISPOSAL ..............................................................95

15. TROUBLESHOOTING ...........................................96

16. SPECIFICATIONS ..................................................98

17. MAJOR Honda DISTRIBUTOR ADDRESSES ...102

18. ‘‘EC DECLARATION OF CONFORMITY’’

CONTENT OUTLINE ...........................................105

19. INDEX ...................................................................110

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1. SAFETY

SAFETY INFORMATION

For your safety and the safety of others, pay special attention to these precautions.

Operator Responsibility

6

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

Read and understand the

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

• Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children.

• Gasoline is extremely flammable and is explosive under certain conditions.

Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored.

• Do not overfill the fuel tank.

After refueling make sure that the fuel filler cap is closed properly and securely.

• Be careful not to spill any fuel while refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled make sure that the area is dry before starting the engine.

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Shift to the neutral position and then shift to the reverse position at low engine speed.

Do not shift to the reverse position suddenly at high engine speed.

Moving parts can injure you.

Install the engine cover after emergency starting the engine. Do not operate the outboard motor without the engine cover.

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

Understand the use of all controls.

• Do not exceed the boat manufacturer’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 anyone falls overboard.

• Do not run the engine while the boat is near anyone in the water.

• Attach the emergency stop switch lanyard securely to the operator.

• Before operating the outboard motor, familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

SAFETY

• Do not attempt to modify the outboard motor.

• Always wear a life-jacket when on board.

• Do not operate the outboard motor without the engine cover. Exposed moving parts can cause injury.

• 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.

KEEP OUT OF REACH OF

CHILDREN.

• Remove the portable 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.

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SAFETY

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

(there should be no fuel in the filler neck). After refueling, tighten the fuel filler cap securely.

If any fuel is spilled, make sure the area is dry before starting the engine.

The engine and exhaust system become very hot during operation and remain hot for a while after stopping.

Contact with hot engine components can cause burns and may ignite some materials.

• Avoid touching a hot engine or exhaust system.

• Allow the engine to cool before performing maintenance or transporting.

Carbon Monoxide Poisoning

Hazard

Exhaust contains poisonous carbon monoxide, a colorless and odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death.

• If you run the engine in an area that is confined, or even partially enclosed, the air can become contaminated with a dangerous amount of exhaust gas. To keep exhaust gas from building up, provide adequate ventilation.

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2. SAFETY LABEL LOCATIONS

These labels and indications warn you of potential hazards that can cause serious injury.

Read the labels, indications and safety notes and precautions described in this manual carefully.

If a label comes off or becomes hard to read, contact your Honda outboard motor dealer for a replacement.

READ OWNER’S MANUAL GEAR SHIFTING

READ OWNER’S MANUAL

EMERGENCY ENGINE STARTING

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SAFETY LABEL LOCATIONS

(Optional equipment for BF5D and BF6A)

GASOLINE FLAMMABLE DANGER

GAZOLINE INFLAMMABLE DANGEREUX

GASOLINA PELIGRO FLAMABLE

(U type)

FUEL CAUTION

CAUTION

KEEP TOTALLY CLOSED WHEN

NOT IN USE. KEEP AWAY FROM

HEAT, SPARKS, AND OPEN FLAME.

SECURE ABOVE DECK IN WELL

VENTILATED AREA. DO NOT USE

FOR LONG TERM FUEL STORAGE.

DO NOT USE FUEL/OIL MIXTURE.

DANGER

HARMFUL OR FATAL IF SWALLOWED.

KEEP OUT OF REACH OF CHILDREN.

IF SWALLOWED, DO NOT INDUCE

VOMITING. CALL A PHYSICIAN

IMMEDIATELY.

GASOLINE FLAMMABLE DANGER

GAZOLINE INFLAMMABLE DANGEREUX

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CE mark location

[U type]

SAFETY LABEL LOCATIONS

CE MARK

(10)

(4)

(5)

(7)

(8)

(9)

(1)

(2)

(3)

(6)

(1) Model Name

(2) Engine family name

(3) Year code

(4) Rated power

(5) Dry mass (weight) (with propeller)

(6) Country of manufacture

(7) Frame number

(8) Manufacture and address

(9) Name and address of authorized representative and importer

(10)The identification number of the notified body

Year code G H J K L M

Year of manufacture 2016 2017 2018 2019 2020 2021

Name and address of manufacturer, authorized representative and importer are written in the “EC Declaration of Conformity” CONTENT OUTLINE in this Owner’s Manual.

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3. COMPONENT IDENTIFICATION

ENGINE COVER

SHIFT LEVER

FUEL FILLER CAP

VENT KNOB

FUEL VALVE

LEVER

FUEL FILLER CAP

STARTER GRIP

THROTTLE GRIP

OIL FILLER CAP/

DIPSTICK

SPARK PLUG

COOLING

WATER CHECK

HOLE

TILT LEVER

TRANSOM ANGLE

ADJUSTING ROD

ANTIVENTILATION

PLATE

12

THROTTLE

FRICTION KNOB

TILLER

HANDLE

HANDLE

STOPPER

CLAMP SCREW

COOLING

WATER INTAKE

PORT

PROPELLER

STERN BRACKET

STEERING FRICTION

BOLT

GEAR OIL

LEVEL PLUG

GEAR OIL

DRAIN PLUG

ENGINE COVER

LATCH

ENGINE OIL

DRAIN BOLT

WASH PLUG

ANODE

METAL

EXHAUST

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FUEL INLET CAP (BF5D and BF6A only)

FUEL INLET (BF5D and BF6A only)

OIL PRESSURE

INDICATOR LIGHT

EMERGENCY

STOP SWITCH

COMPONENT IDENTIFICATION

(Optional equipment for BF5D and BF6A)

FUEL GAUGE

PORTABLE FUEL TANK

FUEL LINE

CONNECTOR

CHOKE

KNOB

EMERGENCY STOP

SWITCH CLIP

BATTERY CHARGE

CABLE (Equipped type)

EMERGENCY STOP

SWITCH LANYARD

FUEL FILLER

CAP

FUEL FILLER CAP

VENT KNOB

FUEL LINE

PRIMER BULB

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4. CONTROLS

Starter Grip

STARTER GRIP

Shift Lever

NEUTRAL

NEUTRAL

SHIFT LEVER

REVERSE

REVERSE FORWARD

FORWARD

Pulling the starter grip operates the recoil starter to crank the engine for starting. Set the shift lever in the

NEUTRAL position before starting.

The “Neutral Starting System” prevents the starter rope from being pulled out for starting the engine unless the shift lever is set in the

NEUTRAL position.

Use the shift lever to run the boat in forward or reverse gear, or to cut off the engine power from the propeller.

There are three positions for the shift lever.

The starter rope can be pulled out for starting the engine with the shift lever in the NEUTRAL position.

FORWARD: The boat moves ahead.

NEUTRAL: The engine power is cut off from the propeller. The boat does not move.

REVERSE: The boat reverses.

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Fuel Valve Lever

ON (BF4A) or

INTERNAL FUEL TANK POSITION

FUEL

VALVE

LEVER

OFF (BF4A) or PORTABLE

FUEL TANK POSITION

(BF5D and BF6A)

(BF4A)

ON

(BF5D and BF6A)

INTERNAL FUEL

TANK POSITION

OFF

PORTABLE

FUEL TANK

POSITION

CONTROLS

(BF4A)

The fuel valve opens and closes the passage between the internal fuel tank and the carburetor.

The fuel valve lever must be in the

ON position for the engine to run.

When the engine is not in use, leave the fuel valve lever in the OFF position to prevent carburetor flooding and to reduce the possibility of fuel leakage.

(BF5D and BF6A)

The fuel valve lever has internal fuel tank position and portable fuel tank position.

When using the internal fuel tank, turn the fuel valve lever to the internal fuel tank position.

When not connecting the portable fuel tank, fuel is shut off at the portable fuel tank position.

When using the portable fuel tank, turn the fuel valve lever all the way to the portable fuel tank position.

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CONTROLS

(BF4A):

LEVER POSITION

ON

OFF

FUNCTION

Fuel from the internal fuel tank is supplied.

Fuel supply is shut off.

Set the fuel valve lever to the “OFF” position during transporting or storing the outboard motor.

Handle Stopper

(BF5D and BF6A):

LEVER POSITION

INTERNAL

FUEL TANK

TILLER

HANDLE

PORTABLE

FUEL TANK

FUNCTION

Fuel from the internal fuel tank is supplied.

• Fuel from the portable fuel tank is supplied.

• If the portable fuel tank is not connected, fuel supply is shut off.

Set the fuel valve lever to the

“PORTABLE FUEL TANK” position during transporting or storing the outboard motor.

HANDLE

STOPPER

The tiller handle can be moved to the bottom direction by turning the handle stopper.

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Choke Knob

CHOKE KNOB

Throttle Grip

THROTTLE GRIP

CONTROLS

Throttle Friction Knob

THROTTLE

FRICTION KNOB

FIX

When the engine is cold, pull the choke knob to start easily. Rich fuel mixture is provided to the engine by pulling the choke knob.

RELEASE

FAST

FAST

START

SLOW

Turn the throttle grip clockwise or counterclockwise to adjust the engine speed. Turning the throttle grip in the direction shown by arrow increases the engine speed.

THROTTLE GRIP

The throttle friction knob adjusts resistance to throttle grip rotation.

Turn the throttle friction knob clockwise to increase friction for holding a throttle setting while cruising.

Turn the throttle friction knob counterclockwise to decrease friction for easy throttle grip rotation.

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CONTROLS

Fuel Primer Bulb

(Optional equipment for BF5D and

BF6A)

ARROW

OUTLET END

Emergency Stop Switch

EMERGENCY

STOP SWITCH

PRESS

Emergency Stop Switch Lanyard/

Clip

EMERGENCY STOP

SWITCH LANYARD

PRIMER BULB

INLET END

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

Before operating the outboard motor, hold the primer bulb so that the outlet end is higher than the inlet end with the arrow mark pointed upward and squeeze the primer bulb until it feels firm. This will ensure that fuel is supplied to the engine.

18

STOP

Press the emergency stop switch once to stop the engine.

EMERGENCY STOP

SWITCH CLIP

The emergency stop switch lanyard is provided to stop the engine immediately when the operator falls overboard or away from the outboard motor.

The engine stops when the clip at the end of the emergency stop switch lanyard is pulled out of the emergency stop switch.

When operating the outboard motor, be sure to attach one end of the emergency stop switch lanyard securely to the operator.

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STOP

EMERGENCY

STOP SWITCH

EMERGENCY

STOP SWITCH

CLIP

CONTROLS

Oil Pressure Indicator Light

EMERGENCY STOP

SWITCH LANYARD

SPARE EMERGENCY

STOP SWITCH CLIP

If the emergency stop switch lanyard is not set, the boat might run out of control when the operator, for example, falls overboard and is not able to operate the outboard motor.

For the sake of the operator’s and the passengers’ safety, be sure to set the emergency stop switch clip located at one end of the emergency stop switch lanyard with the emergency stop switch. Attach the other end of the emergency stop switch lanyard securely to the operator.

OIL PRESSURE

INDICATOR LIGHT

The engine does not start unless the emergency stop switch clip is set on the emergency stop switch.

A spare emergency stop switch clip is provided in the tool bag. Use the spare emergency stop switch clip to make the emergency engine start when the emergency stop switch lanyard is not available as, for example, the operator falls outboard motor.

OIL PRESSURE

INDICATOR

LIGHT

When the engine oil level is low or the engine lubrication system is faulty, the oil pressure indicator light turns off and the engine protection system will limit engine speed.

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CONTROLS

Tilt Lever Anode Metal Cooling Water Check Hole

ANODE

METAL

TILT LEVER

Use the tilt lever to temporarily raise the outboard motor when the boat is running in the shallows, or mooring or anchoring in the shallows.

Raising the tilt lever unlocks the outboard motor and the outboard motor can be tilted. Lowering the tilt lever locks the outboard motor.

Be sure to lower the tilt lever and lock the outboard motor before sailing. The outboard motor could rise when sailing in the reverse gear, resulting in an accidental injury to the passenger(s).

20

The anode metal is a sacrificed metal which protects the outboard motor from corrosion.

Do not paint the anode metal. It deteriorates the function of the anode metal, which can lead to rust and corrosion damage to the outboard motor.

COOLING WATER CHECK HOLE

The cooling water is checked here to see whether it is circulating inside the engine properly.

After starting the engine, check at the cooling water check hole whether the cooling water is circulating through the engine.

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Cooling Water Intake Port Engine Cover Latch

CONTROLS

Steering Friction Bolt

STEERING FRICTION BOLT

COOLING WATER

INTAKE PORT

The engine cooling water is drawn into the engine through this port.

TO DECREASE

FRICTION

TO INCREASE

FRICTION

ENGINE COVER LATCH

Latch/unlatch the engine cover latch to install or remove the engine cover.

The steering friction bolt adjusts steering resistance.

Turn the steering friction bolt clockwise to increase friction for holding a steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.

Turn the steering friction bolt counterclockwise to reduce steering friction.

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CONTROLS

Transom Angle Adjusting Rod

Fuel Filler Cap Vent Knob/Fuel Gauge (Portable Fuel Tank)

(Optional equipment for BF5D and BF6A)

FUEL FILLER CAP

VENT KNOB

FUEL GAUGE

OPEN

CLOSE

TRANSOM ANGLE

ADJUSTING ROD

Use the transom angle adjusting rod to adjust the outboard motor angle properly.

The outboard motor angle can be adjusted to the five angles by changing the adjusting rod position.

(page 28)

The fuel gauge indicates the fuel level in the tank.

When refilling the fuel tank, turn the fuel filler cap vent knob counterclockwise to open and remove the fuel filler cap.

Open the vent by turning the fuel filler cap vent knob 2 or 3 turns counterclockwise all the way before starting the engine.

Turn the fuel filler cap vent knob clockwise and close it securely before transporting or storing the outboard motor.

The fuel filler cap vent knob shuts off the fuel tank from the open air.

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Fuel Filler Cap Vent Knob

(Internal Fuel Tank)

OPEN CLOSE

FUEL

FILLER CAP

Clamp Screws

CLAMP SCREWS

CONTROLS

Fuel Inlet Cap and Fuel Inlet

(BF5D and BF6A)

FUEL INLET

FUEL FILLER CAP

VENT KNOB

The fuel filler cap vent knob shuts off the fuel tank from the open air.

Before operating the outboard motor, turn the fuel filler cap vent knob 2 or

3 turns counterclockwise to open the vent.

When refilling the fuel tank, turn the fuel filler cap vent knob counterclockwise to open and remove the fuel filler cap.

Turn the fuel filler cap vent knob clockwise and close it securely before transporting, tilting or storing the outboard motor.

Use the clamp screws to secure the stern brackets to the transom.

FUEL INLET CAP

Remove the fuel inlet cap and connect the fuel line connector to the fuel inlet when using the portable fuel tank.

Always install the fuel inlet cap if the fuel line connector is not connected.

Be sure the fuel inlet cap is securely installed.

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CONTROLS

Fuel Line Connector

(Portable Fuel Tank)

(Optional equipment for BF5D and BF6A)

FUEL LINE CONNECTOR

FUEL LINE CONNECTOR

(OUTBOARD MOTOR SIDE)

(FUEL TANK SIDE)

The fuel line connector is used to connect the fuel line between the separate fuel tank and the outboard motor.

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Location

5. INSTALLATION

Improperly installed outboard motor can result in the outboard motor dropped into the water, boat not able to cruise straight ahead, engine speed not increase, and much fuel consumption.

We recommend that the outboard motor be installed by an authorized

Honda outboard motor dealer.

Consult the authorized Honda dealer in your area for the Y-OP (User

Optional Parts)/equipments installation and operation.

Applicable Boat

Select the boat suitable for the engine power.

Engine power:

BF4A: 2.9 kW (4 PS)

BF5D: 3.68 kW (5 PS) for U type

3.7 kW (5 PS) for D type

BF6A: 4.4 kW (6 PS)

Power recommendation is indicated on most of the boats.

Do not exceed the boat manufacturer’s power recommendation. Damage and injury may result.

Transom Height

T

Type:

S:

L:

T (Outboard Motor

Transom Height)

434 mm (17.1 in)

561 mm (22.1 in)

Select the outboard motor which is correct for the boat transom height of your boat.

CENTER LINE

Install the outboard motor at the stern, at the center line of the boat.

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INSTALLATION

Installation Height

With the boat in the water, properly loaded, and the engine stopped, check the installed depth of the outboard motor by looking at the antiventilation plate.

BOAT

TRANSOM

HEIGHT

0 – 50 mm

(0 – 2 in)

The correct dimensions differ according to the type of the boats and the configuration of the bottom of the boats. Follow the manufacture’s recommended installation height.

If the outboard motor is installed too low, the boat will squat and be hard to plane, and the engine will spray water that may enter the boat. It will tend to porpoise, and high-speed stability will be reduced.

If the outboard motor is installed too high, that will cause propeller ventilation.

ANTIVENTILATION PLATE

The antiventilation plate of the outboard motor should be

0 – 50 mm (0 – 2 in) below the bottom of the boat.

The water level must be at least 100 mm (4 in) above the antiventilation plate with the engine not running, otherwise the water pump may not receive sufficient cooling water, and the engine will overheat.

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Outboard Motor Attachment

Outboard Motor Angle (Cruising)

INSTALLATION

STERN

BRACKET

INCORRECT

CAUSES BOAT TO ‘‘SQUAT’’

INCORRECT

CAUSES BOAT TO ‘‘PLOW’’

O.K.

SAFETY ROPE CLAMP SCREWS

Attach the stern bracket to the transom and tighten the clamp screws.

• While operating the boat, check the tightness of the clamp screws occasionally.

• Tie a rope through the hole in the stern bracket and secure the other end of the rope to the boat.

This will prevent accidental loss of the outboard motor.

CORRECT

GIVES MAXIMUM PERFORMANCE

Install the outboard motor at the best trim angle for stable cruising and maximum power.

Trim angle too large: Incorrect causes boat to ‘‘squat.’’

Trim angle too small: Incorrect causes boat to ‘‘plow.’’

The trim angle differs according to the combination of the boat, outboard motor, and propeller, and the operating conditions.

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INSTALLATION

<Outboard Motor Angle

Adjustment>

Adjust the outboard motor so that it is perpendicular to the water surface

(i.e. axis of the propeller is parallel with the water surface).

TO CHANGE UNLOCKED

POSITION

(2)

(1)

TRANSOM ANGLE

ADJUSTING ROD

There are five adjusting stages.

1. Push in (1) the transom angle adjusting rod, twist upwards (2) to the unlocked position and pull out to remove.

TRANSOM ANGLE

ADJUSTING ROD

TO LOCK

LOCKED POSITION

2. Inserting the transom angle adjusting rod in the proper hole, twist it down to lock. After locking, pull the transom angle adjusting rod and be sure it is not withdrawn.

To prevent damage to the outboard motor or boat, make sure the adjusting rod is locked.

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32ZVC6000.book Page 29 Thursday, April 28, 2016 10:51 AM

INSTALLATION

Battery Connections

Use a battery which has 12V-28 Ah or more specifications.

The battery is an optional part (i.e. part to be purchased separately from the outboard motor).

Batteries produce explosive gases:

If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

• CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid.

Contact with eyes or skin, even through clothing, may cause severe burns. Wear a faceshield and protective clothing.

• Keep flames and sparks away, and do not smoke in the area.

ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

• POISON: Electrolyte is poison.

ANTIDOTE:

─ External: Flush thoroughly with water.

─ Internal: Drink large quantities of water or milk.

Follow with milk of magnesia or vegetable oil, and call a physician immediately.

• KEEP OUT OF REACH OF

CHILDREN.

Place the battery in the battery box and fix the battery box securely to the hull.

Install the battery box in a location such that it does not topple over while the boat is cruising or is not exposed to spray or direct of sunlight.

(–) TERMINAL

(+) TERMINAL

RED

TERMINAL

COVER

BLACK TERMINAL COVER

Connect the battery charge cables:

1. Connect the cable with the red terminal cover to the positive (+) terminal of the battery.

2. Connect the cable with the black terminal cover to the negative (–) terminal of the battery.

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INSTALLATION

• Be sure to connect the (+) side battery cable first. When disconnecting the cables, disconnect the (–) side first then the (+) side.

• Unless the cables are properly connected to the terminals, the battery is not charged.

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

• Do not disconnect the battery cables while the engine is running. Disconnecting the cables while the engine is running, will damage the outboard motor’s electrical system.

• Do not place the fuel tank near the battery.

Battery Charge Cable

(Equipped type)

BATTERY CHARGE

CABLE

BATTERY

– TO ACCESSORIES

The battery charge cable provides a

12 volt, 6 amp. output for battery charging.

The charging circuit is protected by a

15 amp. fuse that is attached to the battery charge cable.

• Reversing the battery leads will damage the charging system and/ or the battery.

• When it is not in use, keep the

DC charging cable dry and clean by covering it with the insulation sheet.

The outboard motor’s 12 volt output is intended for battery charging only.

Electrical accessories should be connected to the battery as shown.

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The BF4A/BF5D/BF6A are the

4-stroke, water cooled outboard motor which uses unleaded regular gasoline for fuel. It also requires the engine oil. Check the following before operating the outboard motor.

STARTER GRIP

6. PRE-OPERATION CHECKS

Installing Engine Cover

STARTER GRIP

Perform the following pre-operation checks with the engine stopped.

Before each use, look around and underneath the engine for signs of oil or gasoline leaks.

Removing Engine Cover

ENGINE COVER LATCH

ENGINE COVER

ENGINE COVER

ENGINE COVER

HOOK

ENGINE COVER HOOK

• To remove, unlatch the engine cover latch and slide the engine cover forward. Unhook the engine cover hook as shown. Remove the engine cover while turning a starter grip to the upward.

Do not operate the outboard motor without the engine cover.

Exposed moving parts can cause injury.

• To install, lower the engine cover while turning a starter grip to the upward. Hook the engine cover hook as shown, and latch the engine cover latch.

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PRE-OPERATION CHECKS

Engine Oil Level

• Engine oil is a major factor affecting engine performance and service life. Nondetergent and low quality oils are not recommended, because they have inadequate lubricating properties.

• Running the engine with insufficient oil can cause serious engine damage.

<Recommended oil>

Use Honda 4-stroke oil or an equivalent high detergent, premium quality outboard motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for

Service category SG, SH or SJ.

Outboard motor oils category SG, SH or SJ will show this designation on the container.

SAE 10W-30 is recommended for general, all-temperature use.

To avoid incorrect gauging of the engine oil level, inspect the oil level when the engine has cooled.

AMBIENT TEMPERATURE

<Inspection and Refilling>

OIL FILLER CAP/

DIPSTICK

UPPER LEVEL

LOWER LEVEL

1. Position the outboard motor vertically, and remove the engine cover (see page 31).

2. Remove the oil filler cap/dipstick and wipe it with a clean rag.

3. Insert the dipstick and screwing it into the oil filler neck. Remove the dipstick.

Check the oil level shown on the dipstick.

If near or below the lower level mark, fill to the upper level mark with the recommended oil. Tighten the oil filler cap securely.

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When the engine oil is contaminated or discolored, replace with the fresh engine oil (see pages 72 and 74 for replacement interval and procedure).

Oil capacity:

0.55 L (0.58 US qt, 0.48 Imp qt)

4. Install the engine cover and lock it securely by push down the engine cover latch (see page 31).

PRE-OPERATION CHECKS

When you check the oil level with the dipstick, you might notice the engine oil appears milky or the oil level has increased. If you notice either condition, change the engine oil. See the following table for an explanation of these conditions.

Operating Method

Running the engine below

3,000 rpm for more than

30% of the time so the engine does not warm up.

Frequent starting and stopping without allowing the engine to warm up.

Do not overfill the engine oil.

Check the engine oil after refilling.

Excessive engine oil as well as the insufficient oil could cause damage to the engine.

Result

• Water condenses in the engine and mixes with the oil, resulting in a milky appearance.

• Unburned fuel mixes with the oil, increasing the volume of oil.

Effect

The engine oil deteriorates, becomes less efficient as a lubricant, and causes an engine malfunction.

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PRE-OPERATION CHECKS

Fuel Level (Internal Fuel Tank)

FUEL FILLER CAP

UPPER LEVEL

UPPER LEVEL

FUEL FILLER CAP

VENT KNOB

Open the fuel filler cap vent knob

(see page 23).

Remove the fuel filler cap and check the fuel level. Refill the fuel tank if the fuel level is low.

Open the fuel filler cap vent knob before removing the fuel filler cap.

When the fuel filler cap vent knob is firmly closed, the fuel filler cap will be difficult to remove.

After refueling, be sure to tighten the fuel filler cap firmly and close the fuel filler cap vent knob firmly.

34

FUEL TANK

Use unleaded gasoline with a

Research Octane Number of 91 or higher (a Pump Octane Number of 86 or higher). Use of leaded gasoline may cause damage to the engine.

Never use gasoline that is stale, contaminated, or mixed with oil.

Avoid getting dirt, dust or water in the fuel tank.

FUEL TANK CAPACITY:

1.5 L (0.40 US gal, 0.33 Imp gal)

• Gasoline is extremely flammable and is explosive under certain conditions.

• Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.

• Do not overfill the fuel tank

(there should be no fuel in the filler neck). After refueling, make sure the fuel filler cap is closed properly and securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

• Avoid repeated or prolonged contact with skin or breathing of vapor.

• KEEP OUT OF REACH OF

CHILDREN.

32ZVC6000.book Page 35 Thursday, April 28, 2016 10:51 AM

PRE-OPERATION CHECKS

Fuel Level (Portable Fuel Tank)

(Optional equipment for BF5D and BF6A)

FUEL FILLER CAP

VENT KNOB

OPEN

CLOSE

FUEL GAUGE

FUEL FILLER CAP

Open the fuel filler cap vent knob

(see page 22).

Check the fuel gauge and refill the fuel tank if the fuel level is low.

Open the fuel filler cap vent knob before removing the fuel filler cap.

When the fuel filler cap vent knob is firmly closed, the fuel filler cap will be difficult to remove.

After refueling, be sure to tighten the fuel filler cap firmly and close the fuel filler cap vent knob firmly.

Use unleaded gasoline with a

Research Octane Number of 91 or higher (a Pump Octane Number of 86 or higher). Use of leaded gasoline may cause damage to the engine.

Never use gasoline that is stale, contaminated, or mixed with oil.

Avoid getting dirt, dust or water in the fuel tank.

FUEL TANK CAPACITY:

12 L (3.2 US gal, 2.6 Imp gal)

• Gasoline is extremely flammable and is explosive under certain conditions.

• Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.

• Do not overfill the fuel tank

(there should be no fuel in the filler neck). After refueling, make sure the fuel filler cap is closed properly and securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

• Avoid repeated or prolonged contact with skin or breathing of vapor.

• KEEP OUT OF REACH OF

CHILDREN.

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PRE-OPERATION CHECKS

Gasoline Containing Alcohol

If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol, and the other containing methanol.

Do not use gasohol that contains more than 10% ethanol.

Do not use gasoline containing more than 5% methanol (methyl or wood alcohol) and that does not also contain co-solvents and corrosion inhibitors for methanol.

• Fuel system damage or engine performance problems resulting from the use of gasoline that contains more alcohol than recommended is not covered under the warranty.

• Before buying gasoline from an unfamiliar station, first determine if the gasoline contains alcohol, if it does, find out the type and percentage of alcohol used.

If you notice any undesirable operating symptoms while using a particular gasoline. Switch to a gasoline that you know contains less than the recommended amount of alcohol.

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Battery Electrolyte Level

UPPER LEVEL

BATTERY

CAP

LOWER LEVEL

Battery handling differs according to the type of the battery and the instructions described below might not be applicable to the battery of your outboard motor. Refer to the battery manufacturer’s instructions.

Check whether the battery fluid is between the upper and lower levels, and check the vent hole in the battery caps for clogging.

If the battery fluid is near or below the lower level, add the distilled water to the upper level.

Batteries produce explosive gases:

If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

• CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid.

Contact with eyes or skin, even through clothing, may cause severe burns. Wear a faceshield and protective clothing.

• Keep flames and sparks away, and do not smoke in the area.

ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

• POISON: Electrolyte is poison.

ANTIDOTE:

─ External: Flush thoroughly with water.

PRE-OPERATION CHECKS

─ Internal: Drink large quantities of water or milk.

Follow with milk of magnesia or vegetable oil, and call a physician immediately.

• KEEP OUT OF REACH OF

CHILDREN.

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PRE-OPERATION CHECKS

Other Checks

(3)

(5) TOOL KIT (page 71)

(6)

(4)

(2) (Optional equipment for BF5D and BF6A)

Check the following items:

(1) The propeller and cotter pin for damage or looseness.

(2) (Optional equipment for BF5D and

BF6A) The fuel line for kinking, collapsing or a loose connection.

(3) The tiller handle for impaired operation.

(4) The stern bracket for damage and looseness.

(5) The tool kit for missing spare parts and tools. (page 71)

(6) The anode metal for damage, looseness or excessive corrosion.

38

(1)

The anode metal helps to protect the outboard motor from corrosion damage; it must be exposed directly to the water whenever the outboard motor is in use. Replace the anode when it has been reduced to about two-thirds of the original size, or if it is crumbling.

The possibility of corrosion damage is increased if the anode metal is painted over or allowed to deteriorate.

Parts/materials which should be installed on board:

• Owner’s Manual

• Tool kit

• Spare spark plug, engine oil, propeller, shear pin and cotter pin.

• Required information regarding boating laws and regulations.

32ZVC6000.book Page 39 Thursday, April 28, 2016 10:51 AM

7. STARTING THE ENGINE

Priming the Carburetor with Gasoline

(When using the internal fuel tank )

When starting the engine for the first time after purchasing an outboard motor, or when starting the engine after draining the gasoline, pull the starter grip about 10 times without attaching the emergency stop switch clip to fill the carburetor with gasoline.

FUEL FILTER CAP

VENT KNOB

1. Fill fuel to upper level of the internal fuel tank.

2. Open the internal fuel filler cap vent knob 2 to 3 turns counterclockwise.

FUEL

VALVE

LEVER

(BF4A)

ON (BF4A) or

INTERNAL FUEL

TANK POSITION

(BF5D and BF6A)

NEUTRAL

SHIFT LEVER

NEUTRAL

If you do not fill fuel to the upper level of the internal fuel tank, fuel loading to the carburetor may be insufficient.

OPEN

CLOSE

ON

(BF5D and BF6A)

INTERNAL FUEL

TANK POSITION

3. Turn the fuel valve lever to the ON position (BF4A) or internal fuel tank position (BF5D and BF6A).

4. Move the shift lever to the

NEUTRAL position. The starter cannot be operated unless the shift lever is set in the NEUTRAL position.

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STARTING THE ENGINE

Direction to pull

Fuel Tank and Vent Knob (Optional equipment for BF5D and BF6A)

[When using the portable fuel tank]

OPEN

FUEL FILLER CAP

VENT KNOB

CLOSE

STARTER GRIP

5. Pull the starter grip about 10 times.

• Do not allow the starter grip to snap back against the engine.

Return it gently to prevent damage to the starter.

The fuel tank must be properly secured in the boat. This will protect the fuel tank from mechanical damage caused by the fuel tank shifting.

The fuel tank must be in a well-ventilated area to reduce the chance of a gasoline vapor explosion.

Avoid direct sunlight on the fuel tank.

Due to the fuel pump capacity, do not place the fuel tank more than 2 meters

(6.6 feet) away from the outboard motor or lower than 1 meter (3.3 feet) below the outboard motor end fuel line connector.

1. Turn the internal and portable side fuel filler cap vent knobs 2 or 3 turns counterclockwise all the way to open the vent.

Allow the air pressure inside the fuel tank to equalize with the outside air. With the vent open, air can enter the fuel tank to displace the fuel as the fuel level goes down.

2. Remove the fuel filler cap and inspect the condition of the fuel filler cap and gasket. Replace the fuel filler cap or gasket if they are cracked, damaged or leak fuel.

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Fuel Line Connection (Optional equipment for BF5D and BF6A)

[When using the portable fuel tank]

FUEL LINE CONNECTOR

STARTING THE ENGINE

Inspect the fuel line, and the O-ring seals in the fuel line connectors.

Replace the fuel line, or fuel line connectors if they are cracked, damaged or leak fuel. Be sure the fuel line is not kinked.

(FUEL TANK SIDE)

1. Connect the fuel line connector to the fuel tank. Be sure the fuel line connector is securely snapped in place.

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STARTING THE ENGINE

FUEL LINE

CONNECTOR

ARROW

OUTLET END

(TO OUTBOARD

MOTOR)

PRIMER BULB

FUEL

INLET

CAP

CLIP

(OUTBOARD MOTOR SIDE)

2. Remove the fuel inlet cap.

3. Connect the fuel line connector to the outboard motor with the clip toward the starboard side as shown.

Be sure the fuel line connector is securely snapped in place.

4. Turn the fuel valve lever to the portable fuel tank position (see page 15).

Always disconnect the fuel line and install fuel inlet cap when storing, tilting or transporting the outboard motor.

If the outboard motor end fuel line connector is forcibly installed in the reversed direction, the fuel line connector O-ring seal can be damaged. A damaged O-ring seal can cause a fuel leak.

INLET END

(TO FUEL TANK)

5. 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 carburetor. Check for fuel leaks and repair any leaks before starting the engine.

Do not touch the primer bulb with the engine running or when tilting up the outboard motor.

The carburetor could overflow.

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STARTING THE ENGINE

Starting the Engine

Exhaust contains poisonous carbon monoxide which can cause unconsciousness and may lead to death.

Never run the outboard motor in a closed garage or confined area.

The propeller and cooling water intake port must be lowered into the water, running the outboard motor out of the water will damage the water pump and overheat the engine.

(When using the internal fuel tank)

Prime the carburetor with gasoline.

When starting the engine for the first time after purchasing an outboard motor, or when starting the engine after draining the gasoline (see page

39).

(When using the portable fuel tank)

Connect the fuel line (see page 40).

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY

STOP SWITCH

CLIP 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 seriously injure the operator, passengers, or bystanders. Always properly attach the lanyard before starting the engine.

STOP

SPARE EMERGENCY

STOP SWITCH CLIP

1. Engage the emergency stop switch clip at one end of the emergency stop switch lanyard into the emergency stop switch. Attach the other end of the emergency stop switch lanyard securely to the operator.

• The engine will not start unless the emergency stop switch clip is engaged with the emergency stop switch.

• A spare emergency stop switch clip is provided in the tool bag.

Use the spare emergency stop switch clip to make the emergency engine start when the emergency stop switch lanyard is not available as, for example, the operator falls outboard motor.

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STARTING THE ENGINE

(Internal fuel tank)

OPEN

CLOSE

1.

(When using the internal fuel tank)

Open the fuel filler cap vent knob 2 to 3 turns counterclockwise.

(When using the portable fuel tank)

Open the internal and portable side fuel filler cap vent knobs 2 or 3 turns counterclockwise all the way to open the vent.

FUEL FILLER CAP

VENT KNOB

(Portable fuel tank)

FUEL FILLER CAP

VENT KNOB

OPEN

Always open the internal fuel filler cap vent knob when using the portable fuel tank.

ON (BF4A) or

INTERNAL FUEL TANK POSITION

CLOSE

FUEL

VALVE

LEVER

OFF (BF4A) or PORTABLE

FUEL TANK POSITION

(BF5D and BF6A)

(BF4A)

ON

(BF5D and BF6A)

OFF

PORTABLE

FUEL TANK

POSITION

INTERNAL FUEL

TANK POSITION

2.

(When using the internal fuel tank)

Turn the fuel valve lever to the ON position (BF4A) or internal fuel tank position (BF5D and BF6A).

(When using the portable fuel tank)

Turn the fuel valve lever to the portable fuel tank position.

44

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STARTING THE ENGINE

CHOKE KNOB

MARK

NEUTRAL

ON

SHIFT LEVER

NEUTRAL

THROTTLE GRIP

START

3. Move the shift lever to the

NEUTRAL position. The recoil starter cannot be operated unless the shift lever is set in the

NEUTRAL position.

4. Align the “ ” mark on the throttle grip with the projected end of the

“ ► ” mark on the handle.

5. When the engine is cold or ambient temperature is low, pull the choke knob to the ON position.

(It provides rich fuel mixture to the engine.)

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STARTING THE ENGINE

Direction to pull

OIL PRESSURE

INDICATOR LIGHT

STARTER GRIP

6. Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown above.

• Do not allow the starter grip to snap back against the engine.

Return it gently to prevent damage to the starter.

• Do not pull the starter grip while the engine is running, as that may damage the starter.

• The “Neutral Starting System” prevents the starter rope from being pulled out for starting the engine unless the shift lever is set in the

NEUTRAL position.

• If the engine fails to start, check the emergency stop switch clip.

OIL PRESSURE

INDICATOR

LIGHT

7. After the engine starts, confirm that the engine oil pressure indicator light is lit. In the event that the indicator is not lit, stop the engine and perform the following checks.

1) Is the oil quantity normal?

2) If the oil quantity is correct but the indicator lamp is not lit, have the outboard motor checked by the shop where you purchased it.

46

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STARTING THE ENGINE

O.K.

NORMAL FLOW

INTAKE

OBSTRUCTED

COOLING WATER CHECK HOLE

8. After starting, check whether the cooling water is flowing out of the cooling water check hole. Amount of water flowing out of the check hole might vary due to the thermostat operation, but this is normal.

obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by an authorized Honda outboard motor dealer. Do not operate the engine until the problem has been corrected.

9. If the choke was used, push it in gradually as the engine warms up.

If water does not flow out, or if steam comes out, stop the engine.

Check to see if the cooling water intake port is

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STARTING THE ENGINE

Emergency Starting

If the recoil starter does not operate properly for some reasons, the engine can be started using the emergency starter rope that came with your outboard motor.

NEUTRAL

The ‘‘Neutral Starting System’’ will not work in emergency starting. Be sure to set the shift lever into

NEUTRAL position to prevent start-in-gear when starting the engine in emergency. Sudden unexpected acceleration could result in serious injury or death.

2. Remove the engine cover (see page

31).

THROTTLE CABLES

SHIFT LEVER

COVER HOOKS

NEUTRAL START CABLE

4. Release the neutral start cable from the cover hooks.

NEUTRAL

1. Move the shift lever in the

NEUTRAL position.

48

COVER HOOK

3. Release the throttle cables from the cover hook.

NEUTRAL START CABLE

5. Disconnect the neutral start cable from recoil case.

32ZVC6000.book Page 49 Thursday, April 28, 2016 10:51 AM

THOROTTLE CABLES

STARTING THE ENGINE

6 mm FLANGE BOLT

(Tighten by hand)

6 mm FLANGE

BOLTS AND

WASHERS

RECOIL

CASE

6 mm CAP

NUTS AND

WASHERS

6. Remove the two 6 mm cap nuts, two washers, two 6 mm flange bolts and two washers. Remove the recoil case.

6 mm FLANGE BOLT

(Tighten by hand)

CABLE HOOK

7. Install and tighten the 6 mm flange bolts by hand.

8. Hook the throttle cables to the cable hook.

NEUTRAL START CABLE

9. Hook the neutral start cable to the under case.

Take care not to lose the bolts, nuts and washers.

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STARTING THE ENGINE

NEUTRAL

EMERGENCY

STOP SWITCH

SHIFT LEVER

NEUTRAL

STOP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

10.Make sure the shift lever in the

NEUTRAL position.

The shift lever into NEUTRAL position to prevent start-in-gear when starting the engine in emergency. Sudden unexpected acceleration could result in serious injury or death.

50

The propeller and cooling water intake port must be lowered into the water, running the outboard motor out of the water will damage the water pump and overheat the engine.

11.Engage the emergency stop switch clip (located at one end of the emergency stop switch lanyard) with the emergency stop switch.

Attach the other end of the emergency stop switch lanyard securely to the operator.

32ZVC6000.book Page 51 Thursday, April 28, 2016 10:51 AM

CHOKE KNOB

MARK

STARTING THE ENGINE

NOTCH

STARTER

PULLEY

STARTER ROPE

ON

12.When the engine is cold or ambient temperature is low, pull the choke knob to the ON position.

(It provides rich fuel mixture to the engine.)

START

THROTTLE GRIP

13.Align the ‘‘ ’’ mark on the throttle grip with the projected end of the ‘‘ ’’ mark on the handle.

KNOTTED END

14.Set the knotted end of the emergency starter rope in the notch in the starter pulley, and while pulling the emergency starter rope clockwise around the starter pulley.

15.Pull the starter rope lightly until resistance is felt, then pull briskly.

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32ZVC6000.book Page 52 Thursday, April 28, 2016 10:51 AM

STARTING THE ENGINE

16.If you pulled out the choke knob to the ON position to start the engine, return it slowly to the OFF position, and turn the throttle grip in the SLOW direction to a position where the engine does not stall.

Keep clear of moving parts.

17.Reinstall the engine cover (see page 31).

(Do not install flywheel cover.)

18.Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing.

19.After returning to the closest boat landing, contact your closest authorized Honda outboard motor dealer and perform the following.

• Have the starting system and electrical system checked.

• Have your dealer reassemble the parts removed in the emergency starting procedure.

Take extreme care when installing the engine cover. The flywheel is rotating. Do not operate without the engine cover. Exposed moving parts could cause injury and starter may damage the engine.

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STARTING THE ENGINE

Troubleshooting Starting Problems

SYMPTOM

The engine doesn’t start.

POSSIBLE CAUSE

Starter grip cannot be pulled out for starting the engine.

Emergency stop switch clip is not engaged.

Fuel filler cap vent knob not open.

Fuel valve lever is not turned to the appropriate position.

Primer bulb not squeezed.

(When using the portable fuel tank)

Engine flooded.

No sparks across spark plug.

Fuel does not reach the carburetor.

Out of fuel.

REMEDY

Set shift lever in NEUTRAL position.

(page 45)

Engage the emergency stop switch clip.

(page 43)

Open fuel filler cap vent knob. (page 44)

Turn the fuel valve lever to the appropriate position. (page 15)

Squeeze primer bulb to supply fuel.

(page 42)

Clean and dry spark plug. (page 78)

Install plug cap securely. (page 79)

Loosen the carburetor drain screw to see if there is fuel in the carburetor float bowl.

(page 90)

Supply fuel. (page 34, 35)

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8. OPERATION

Break-in Procedure

Break-in operation allows the mating surfaces of the moving parts to wear 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 10% to

30% throttle opening.

• Next 60 minutes: Run the outboard motor up to maximum of 50% to

80% throttle opening. Short bursts of full throttle are acceptable but do not operate the outboard motor continuously at full throttle.

• Next 8 hours: Avoid continuous full throttle operation (100% throttle opening). Do not run the outboard motor at full throttle for more than 5 minutes at a time.

Gear Shifting

NEUTRAL

SHIFT LEVER

REVERSE

The shift lever has three positions:

FORWARD, NEUTRAL, and

REVERSE.

An indicator at the base of the shift lever aligns with the icon attached at the base of the shift lever.

Turn the throttle grip to SLOW to decrease engine speed before moving the shift lever.

54

NEUTRAL

REVERSE FORWARD

FORWARD

Do not turn the throttle grip in the

FAST direction in REVERSE and

NEUTRAL gear.

32ZVC6000.book Page 55 Thursday, April 28, 2016 10:51 AM

OPERATION

Steering

SLOW

THROTTLE GRIP

TO INCREASE

FRICTION

TO DECREASE

FRICTION

The boat swings its stern in the opposite direction in which it is to turn. To turn to the right, swing the tiller handle to the left. To turn to the left, swing the tiller handle to the right.

STEERING FRICTION BOLT

For smooth steering, adjust the steering friction bolt so that a slight drag is felt when turning.

SLOW

When operating in reverse, proceed with caution to avoid hitting any underwater obstruction with the propeller.

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OPERATION

Cruising

SHIFT LEVER

FORWARD

THROTTLE GRIP

56

FIX

FAST

THROTTLE

FRICTION KNOB

RELEASE

THROTTLE GRIP

FAST

FORWARD

1. With the shift lever in the

FORWARD position, turn the throttle grip in the FAST direction to increase the speed.

2. For normal cruising, open the throttle about 3/4 turn.

To hold the throttle grip at a steady setting, turn the throttle friction knob clockwise. To free the throttle grip for manual speed control, turn the throttle friction knob counterclockwise.

• Do not operate without the engine cover. Exposed moving parts could cause injury; water may damage the engine.

• Confirm that the tilt lever is in the ‘‘RUN’’ position.

For best performance, passengers and equipment should be distributed evenly to balance the boat.

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Tilting the Outboard Motor

Tilt the outboard motor to prevent the propeller and gear case from hitting the bottom when the boat is beached or stopped in shallow water.

1. Move the shift lever to the

NEUTRAL position and stop the engine. (see page 14).

2. Turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (see page 15).

3. Close the internal fuel tank vent by turning the vent knob clockwise all the way (see page 23).

4. When using a portable fuel tank, close the internal and portable fuel tank vents by turning the vent knob clockwise all the way (see page 22,

23), disconnect the fuel line connector from the outboard motor and install the fuel inlet cap (see page 23).

NEUTRAL

SHIFT LEVER

NEUTRAL

OPERATION

GRIP

5. Move the tilt lever to the “TILT” position. Hold the engine cover grip and raise the outboard motor.

Do not use the tiller handle to tilt the outboard motor.

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

Stop the engine and disconnect the fuel line from the outboard motor before tilting the outboard motor.

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OPERATION

TILT LEVER

58° (when mooring) 34°

18° (when cruising in shallow water)

6. Set the tilt lever in the “TILT” position, and raise the outboard motor to any of the 18°, 34° and

58° tilt position.

7. To return the outboard motor to the normal “RUN” position, move the tilt lever away from you until it stops, tilt the outboard motor slightly, then lower the outboard motor slowly.

• Make sure water comes out from the cooling water check hole.

• When the outboard motor is tilted up, cruise at low speed.

• Never operate in reverse when the outboard motor is tilted up.

The outboard motor will rise up, causing an accident.

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<Mooring>

NO!

To avoid damaging the outboard motor, use the utmost care when mooring a boat, especially when its outboard motor is tilted up. Don’t allow the outboard motor to strike against the pier or other boats.

OPERATION

<Over-rev Limiter>

This outboard motor is equipped with an engine over-rev limiter which activates when the engine speed increases excessively. The over-rev limiter can be activated while cruising, tilting up the outboard motor, or when ventilation occurs during a sharp turn.

When the over-rev limiter is activated:

1. Reduce the throttle opening immediately and check the trim angle.

2. If the trim angle is correct but the over-rev limiter stays activated, stop the engine, check the condition of the outboard motor, check to see if the correct propeller is installed and check it for damage.

Correct or service as necessary, by contacting your authorized Honda outboard motor dealer.

Close the internal fuel tank vent by turning the vent knob clockwise all the way. If you will be storing the outboard motor.

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OPERATION

Cruising in Shallows

When cruising in shallows, tilt up the outboard motor to prevent the propeller and gear case from hitting bottom.

Refer to “Tilting the Outboard

Motor” (page 57) for the procedure.

• Be sure that the water is coming out of the cooling water check hole.

• When the outboard motor is tilted up, cruise at low speed.

High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase.

A very rich mixture will also foul the spark plug and cause hard starting.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate the outboard motor at altitudes higher than 1,500 m (5,000 feet) above sea level, have your authorized Honda dealer perform these carburetor modifications.

Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 300 m

(1,000 feet) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When the carburetor have been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use.

Operation at altitudes below 1,500 m (5,000 feet) with modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have an authorized

Honda outboard motor dealer return the carburetor to original factory specifications.

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9. STOPPING THE ENGINE

Stopping the Engine

EMERGENCY STOP

SWITCH CLIP

SLOW

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

PULL

THROTTLE GRIP

NEUTRAL

• In an emergency;

Disengage the emergency stop switch clip from the emergency 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 emergency stop switch is operating properly.

SHIFT LEVER

• In normal use;

1. Turn the throttle grip to SLOW position and move the shift lever to

NEUTRAL.

SLOW

NEUTRAL

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STOPPING THE ENGINE

EMERGENCY

STOP SWITCH

STOP

PRESS

2. Press the emergency stop switch once to stop the engine.

After sailing with the throttle fully open, cool down the engine by running it at the idle speed for a few minutes.

In the event that the engine does not stop when you press the emergency stop switch, and pull the emergency stop switch lanyard. If the engine continues to run, pull the choke knob to stop the engine.

3. Remove the emergency stop switch lanyard and store it.

4. If you are using the internal fuel tank, turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (see page 15) and close the internal fuel tank vent by turning the vent knob clockwise all the way

(see page 23). If you will be storing, tilting or transporting the outboard motor.

If you are using a portable fuel tank, close the internal and portable fuel tank vents by turning the vent knob clockwise all the way (see page 22,23) and disconnect the fuel line and install fuel inlet cap if you

62 will be storing, tilting or transporting the outboard motor.

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Before transporting the outboard motor:

If you are using the internal fuel tank, turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank position (BF5D and BF6A) (see page

15) and close the internal fuel tank vent by turning the vent knob clockwise all the way (see page 23).

If you are using a portable fuel tank, close the internal and portable fuel tank vents by turning the vent knob clockwise all the way (see page 22,

23) and disconnect the fuel line in the following procedure and install fuel inlet cap.

Be sure the fuel inlet cap is securely installed.

Close the internal fuel tank vent by turning the vent knob clockwise all the way. If you will be storing, tilting or transporting the outboard motor.

10. TRANSPORTING

Fuel Line Removal (Optional equipment for BF5D and BF6A)

FUEL LINE CONNECTOR

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death.

• Be careful not to spill fuel.

Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before storing or transporting the outboard motor.

• Do not smoke or allow flames or sparks where fuel is drained or stored.

In cold weather, to prevent ice from forming inside the water pump, raise the outboard motor out of the water, remove the emergency stop switch clip and pull the starter grip several times to flush out the water.

CLIP

1. While pressing the fuel line connector clip, pull the fuel line connector and disconnect it from the outboard motor side joint and install the fuel inlet cap.

FUEL LINE

CONNECTOR

2. While pulling the fuel line connector cover, pull the fuel line connector to disconnect the fuel line connector from the portable fuel tank.

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TRANSPORTING

Transporting

CARRYING HANDLE

NO!

Carry the outboard motor with more than two people. To carry, hold the outboard motor by the carrying handle, or hold by the carrying handle and the engine under cover as shown here. Do not carry by the engine cover.

Do not carry the outboard motor by the engine cover. The engine cover can be unlatched and outboard motor can drop, resulting in an accidental injury and damage.

To avoid damaging the outboard motor, never use it as a handle for lifting or moving the boat.

Close the internal fuel tank vent by turning the vent knob clockwise all the way or drain the gasoline. If you will be transporting the outboard motor.

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Transport the outboard motor either vertically or horizontally as follows with the tiller handle raised.

STERN BRACKET

TRANSPORTING

Vertical transport

MOTOR

STAND

1. Attach the stern brackets to a motor stand and mount the outboard motor to the brackets.

2. Move the shift lever to the

REVERSE position and lock the tilt lever.

3. Transport the outboard motor with the tiller handle raised.

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TRANSPORTING

Horizontal transport

INCORRECT

CASE PROTECTORS PROTECTOR

Rest the outboard motor on the case protectors. (With tiller handle side of the outboard motor upward)

Always rest the outboard motor on a protector and be sure to protect it from impact and damage.

Any other transport or storage position may cause damage or oil leakage.

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Trailering

TO INCREASE

FRICTION

TO DECREASE

FRICTION

STEERING FRICTION BOLT

When trailering or transporting the boat with the outboard motor attached always disconnect the fuel line from the portable fuel tank, install the fuel inlet cap and tighten the steering friction bolt securely.

Do not trailer or transport the boat with the outboard motor in the tilted position. The boat or outboard motor could be severely damaged if the outboard motor drops.

The outboard motor should be trailed in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilted position using a motor support device such as a transom saver bar, or remove the outboard motor from the boat. Tilt lever should be in the tilted position.

TRANSPORTING

Close the internal fuel tank vent by turning the vent knob clockwise all the way or drain the gasoline. If you will be transporting the outboard motor.

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11. CLEANING AND FLUSHING

After each use in salt water or dirty water, thoroughly clean and flush the outboard motor with fresh water.

With Water Hose Joint

(Optional equipment)

WATER HOSE

JOINT

• For safety, the propeller must be removed.

• Be sure the outboard motor is securely mounted, and do not leave it unattended while running.

• Keep children and pets away from the area, and stay clear of moving parts during this procedure.

Running the engine without water can cause serious engine damage due to overheating. Be sure that water flows from the cooling water check hole while the engine is running. If not, stop the engine and determine the cause of the problem.

WATER HOSE

JOINT

HOSE

1. Tilt down the outboard motor.

2. Wash the outside of the outboard motor with clean, fresh water.

3. Remove the wash plug.

4. Flush the cooling system, using the water hose joint.

a. Attach a hose from a fresh water faucet to the water hose joint.

b. Remove the propeller (see page

87).

c. Turn on the fresh water supply to the hose.

NEUTRAL

SHIFT LEVER

NEUTRAL d. Start the engine and run in neutral position for at least 10 minutes to clean inside of the engine.

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5. After flushing, stop the engine.

If you are using the internal fuel tank, turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (see page 15) and close the internal fuel tank vent by turning the vent knob clockwise all the way

(see page 23).

If you are using a portable fuel tank, close the internal and portable fuel tank vents by turning the vent knob clockwise all the way (see page 22, 23) and disconnect the fuel line and install fuel inlet cap.

6. Remove the hose joint, and reinstall the wash plug and the propeller (see page 87).

7. Tilt up the outboard motor and move the tilt lever to the LOCK position.

CLEANING AND FLUSHING

Without Water Hose Joint

ANTIVENTILATION PLATE

When the water hose joint is not used, stand the outboard motor in a suitable container of fresh water.

1. Tilt down the outboard motor.

2. Wash the outside of the outboard motor with clean, fresh water.

3. Remove the propeller (see page

87).

4. Stand the outboard motor in a suitable container of water. The water level must be at least 100 mm (4 in) above the antiventilation plate.

5. Start the engine and run slowly for at least 5 minutes.

6. After flushing, stop the engine.

If you are using the internal fuel tank, turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (see page 15) and close the internal fuel tank vent by turning the vent knob clockwise all the way

(see page 23).

If you are using a portable fuel tank, close the internal and portable fuel tank vents by turning the vent knob clockwise all the way (see page 22, 23) and disconnect the fuel line and install fuel inlet cap.

7. Remove the water container, and reinstall the propeller (see page

87).

8. Tilt up the outboard motor and move the tilt lever to the LOCK position.

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12. MAINTENANCE

Periodic maintenance and adjustment are important to keep the outboard motor in the best operating condition.

Service and inspect according to the

MAINTENANCE SCHEDULE.

Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated.

Never run the engine in an enclosed or confined area.

Exhaust contains poisonous carbon monoxide gas; exposure can cause loss of consciousness and may lead to death.

Be sure to reinstall the engine cover, if it was removed, before starting the engine. Lock it securely by pulling up the lock lever.

• If the engine must be run, make sure there is water at least

100 mm (4 in) above the antiventilation plate, otherwise the water pump may not receive sufficient cooling water, and the engine will overheat.

• Use only Honda Genuine parts or their equivalents for maintenance or repair. The use of replacement parts which are not of equivalent quality may damage the outboard motor.

• To maintain cooling system efficiently, flush the outboard motor with fresh water after each use in salt water or dirty water.

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Tool Kit and Spare Parts

The following tools and spare parts are supplied with the outboard motor for maintenance, adjustment, and emergency repairs.

Spare shear pin and cotter pin are located inside the engine compartment above the engine under cover.

TOOL KIT

10 × 12 mm

WRENCH

FLAT

SCREWDRIVER

GRIP

EMERGENCY

STARTER ROPE

PLIERS

SPARK PLUG

WRENCH

MAINTENANCE

TOOL BAG

EMERGENCY STOP

SWITCH CLIP

Spare Parts

SPARE SHEAR

PIN

SPARE COTTER PIN

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MAINTENANCE

MAINTENANCE SCHEDULE

ITEM

Engine oil

REGULAR SERVICE PERIOD (3)

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

Gear case oil

Starter rope

Carburetor linkage

Valve clearance

Spark plug

Propeller and Cotter pin

Anode

Idling speed

Lubrication

Fuel tank and tank filter

(Internal)

Fuel tank and tank filter

(Portable)

Thermostat

Check level

Change

Change

Check

Check-adjust

Check-adjust

Check-adjust

Replace

Check

Check

Check-adjust

Grease

Clean

Clean

Check

Each use o o o (8)

After use

First month or

20 hrs.

Every 6 months or

100 hrs.

Every year or

200 hrs.

o o o (2) o (2) o (2) o (1) o o o o (2) o o (2) o (1) o (2) o (2) o

Refer to page

78

78

-

-

32

74

76

77

38

38

-

82

-

85

o o (2)

(1) Lubricate more frequently when used in salt water.

(2) These items should be serviced by an authorized Honda Marine dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda Shop Manual for service procedures.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

(8) When there is 1/3 or more consumption, please exchange.

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MAINTENANCE

ITEM

Fuel filter

REGULAR SERVICE PERIOD (3)

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

Fuel line

Bolts and Nuts

Breather tube

Cooling water passages

Water pump

Emergency stop switch

Engine oil leak

Each operation part

Engine condition (7)

Check

Replace

Check

Replace

Check-tightness

Check

Clean

Check

Check

Check

Check

Check

Each use o (5) o o o o

After use

First month or

20 hrs.

Every 6 months or

100 hrs.

o

Every year or

200 hrs.

o

Every 2 years (If necessary) (2) (6) o (2) o (2) o (4) o (2) o (2)

Refer to page

83

83

38, 41

-

-

-

68, 69

-

18, 19

-

-

-

(2) These items should be serviced by an authorized Honda Marine dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda Shop Manual for service procedures.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

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

(5) Check the fuel line for leaks, cracks or damage. If it is leaking, cracked or damaged, take it to your servicing dealer for replacement before using your outboard motor.

(6) Check the fuel line for leaks, cracks or damage. Replace the fuel line if there are signs of leaks, cracks or damage.

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

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MAINTENANCE

Engine Oil Change

Insufficient or contaminated engine oil adversely affects the service life of the sliding and moving parts.

Wash your hands with soap and water after handling used oil.

Oil change interval:

20 operating hours after the date of purchase or first month for initial replacement, then every 100 operating hours or 6 months.

Oil capacity:

0.55 L (0.58 US qt, 0.48 Imp qt)

Recommended oil:

SAE 10W-30 engine oil or equivalent, API Service category SG,

SH or SJ.

<Engine Oil Replacement>

OIL FILLER CAP/DIPSTICK

Drain the oil while the engine is still warm to assure rapid and complete draining.

1. Position the outboard motor vertically, and remove the engine cover (see page 31). Remove the oil filler cap/dipstick.

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MAINTENANCE

UPPER LEVEL 0.55 L

(0.58 US qt, 0.48 Imp qt)

DIPSTICK

LOWER LEVEL 0.45 L

(0.48 US qt, 0.40 Imp qt)

DRAIN BOLT

2. Remove the engine oil drain bolt and sealing washer, and drain the engine oil.

Install a new sealing washer and drain bolt, and tighten bolt securely.

OIL DRAIN BOLT TORQUE:

33 N·m (3.4 kgf·m , 24 lbf·ft)

3. Refill to the upper level mark on the dipstick with the recommended oil. Insert the dipstick screwing it in, then remove it and check the oil level shown on the dipstick.

4. Reinstall the oil filler cap securely.

5. Install the engine cover and lock it securely by push down the engine cover latch (see page 31).

Please dispose of used outboard 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 for reclamation. Do not throw it in the trash or pour it on the ground.

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MAINTENANCE

Gear Oil Change

Oil change interval:

20 hours or first month after initial use for initial change, then every 6 months or 100 operating hours.

Oil capacity:

0.10 L (0.11 US qt, 0.09 Imp qt)

Recommended Oil:

SAE #90 Hypoid gear oil or equivalent, API Service

Classification (GL-4)

Change the gear oil with the engine stopped and the outboard motor in the vertical position.

1. Place a suitable container below the oil drain hole to catch the used oil, then remove the oil level plug, oil drain plug and washers.

LEVEL PLUG

DRAIN PLUG

2. Allow the used oil to drain completely, then install an oil pump adapter in the oil drain hole. If water or contaminated

(milky-colored) oil flows out the drain hole when the plug is removed, have the outboard motor checked by authorized Honda

Marine dealer.

3. Add oil through the oil drain hole until it flows out the oil level hole, then install the oil level plug, oil drain plug and new washers.

GEAR OIL BOTTLE

OIL LEVEL PLUG TORQUE:

3.5 N·m (0.36 kgf·m , 2.6 lbf·ft)

Avoid losing more than 30 cm

3

(1 US oz, 1.1 Imp oz) while reinstalling the drain plug.

OIL DRAIN PLUG TORQUE:

3.5 N·m (0.36 kgf·m , 2.6 lbf·ft)

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Starter Rope Check

STARTER ROPE

Check the starter rope every 6 months or after every 100 operating hours.

Replace the rope if it is frayed.

MAINTENANCE

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MAINTENANCE

Spark Plug Service

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

SPARK PLUG WRENCH

New plug Plug needing replacement

The spark plug becomes very hot during operation and will remain hot to awhile after stopping the engine.

Check-Adjust interval:

Every 100 operating hours or

6 months.

Replace interval:

Every 200 operating hours or every year.

Recommended spark plug:

BKR6E-E (NGK)

Use only the recommended spark plug or equivalent. Spark plug which have an improper heat range may cause engine damage.

SPARK PLUG CAP

1. Remove the engine cover (see page

31).

2. Remove the spark plug cap.

3. Use the wrench and screwdriver to remove the spark plug.

4. Inspect the spark plug.

(1) If the electrode is heavily corroded or carbon-soiled, clean with a wire brush.

(2) Replace a spark plug if the central electrode is worn.

The spark plug can wear out in different ways.

If the sealing washer shows signs of wear, or if the insulator is cracked or chipped, replace the spark plug.

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SIDE ELECTRODE

0.6 – 0.7 mm

(0.024 – 0.028 in)

SEALING WASHER

INSULATOR

6. Check the spark plug washer is in good condition, and thread the plug in by hand to prevent cross threading.

7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer.

SPARK PLUG TORQUE:

18 N·m (1.8 kgf·m , 13 lbf·ft)

5. Measure the plug gap with a feeler gauge.

The gap should be 0.6 – 0.7 mm

(0.024 – 0.028 in). Correct as necessary by carefully bending the side electrode.

If installing new spark plug, tighten

1/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten 1/8 – 1/4 turn after the spark plug seats to compress the washer.

The spark plug must be securely tightened. An improperly tightened plug can become very hot and may cause engine damage.

8. Reinstall the spark plug cap.

9. Reinstall the engine cover.

MAINTENANCE

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MAINTENANCE

Battery Service

Battery handling differs according to the type of the battery and the instructions described below might not be applicable to the battery of your outboard motor. Refer to the battery manufacturer’s instructions.

Check that the battery cables are connected securely.

If the battery terminals are contaminated or corroded, remove the battery and clean the terminals.

Battery check interval:

Before each use.

Batteries produce explosive gases:

If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

• CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid.

Contact with eyes or skin, even through clothing, may cause severe burns. Wear a faceshield and protective clothing.

• Keep flames and sparks away, and do not smoke in the area.

ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

• POISON: Electrolyte is poison.

ANTIDOTE

─ External: Flush thoroughly with water.

─ Internal: Drink large quantities of water or milk.

Follow with milk of magnesia or vegetable oil, and call a physician immediately.

• KEEP OUT OF REACH OF

CHILDREN.

Installation check:

Check that the cables are connected to the battery terminals securely.

Tighten the terminals if they are loose.

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<Battery Cleaning>

NEGATIVE (–)

TERMINAL

POSITIVE (+)

TERMINAL

RED

TERMINAL

COVER

3. Connect the battery positive (+) cable (red terminal cover) to the battery positive (+) terminal, then the battery negative (–) cable

(black terminal cover) to the battery negative (–) terminal.

Tighten the bolts and nuts securely.

Coat the battery terminals with grease.

BLACK TERMINAL COVER

1. Disconnect the battery cable at the battery negative (–) terminal, then at the battery positive (+) terminal.

2. Remove the battery and clean the battery terminals and battery cable terminals with a wire brush or sand paper.

Clean the battery with a solution of baking soda and warm water, taking care not to get the solution or water in the battery cells. Dry the battery thoroughly.

When disconnecting the battery cable, be sure to disconnect at the battery negative (–) terminal first.

To connect, connect at the positive

(+) terminal first, then at the negative (–) terminal. Never dis/connect the battery cable in the reverse order, or it causes a short circuit when a tool contacts the terminals.

MAINTENANCE

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MAINTENANCE

Lubrication

Wipe the outside of the engine with a cloth dipped in clean oil. Apply marine anticorrosion grease to the following parts:

Lubrication interval:

20 operating hours or a month after the date of purchase for initial lubrication, then every 100 operating hours or

6 months.

Apply anticorrosion oil to pivot surfaces where grease cannot penetrate.

HANDLE PIVOT

SHIFT SHAFT

SWIVEL CASE

CLAMP SCREWS

TILT LEVER/REVERSE

LOCK LEVER

PROPELLER SHAFT

TILT LINKAGE

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Fuel Filter Check/Replacement

The fuel filter is located between the fuel valve and the fuel pump.

Water or sediment accumulated in the fuel filter can cause loss of power or hard starting. Check and replace the fuel filter periodically.

Inspection interval:

Every 100 operating hours or 6 months.

Replacement interval:

Every 200 operating hours or every year.

• Gasoline is extremely flammable, and gasoline 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.

• Be sure that any fuel drained from the outboard motor is stored in a safe container.

• Be careful not to spill 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.

MAINTENANCE

<Inspection>

1. Remove the engine cover (see page

31).

2. Check the fuel filter for water accumulation and clogging.

3. Install the engine cover (see page

31).

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MAINTENANCE

<Replacement>

FUEL TUBES

FUEL FILTER

TUBE CLAMPS

1. Turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (see page 15).

2. Close the internal fuel tank vent by turning the vent knob clockwise all the way (see page 23).

3. When using the portable fuel tank, close the internal and portable fuel tank vent by turning the vent knob clockwise all the way (see page

22,23) and disconnect the fuel line connector from the outboard motor

84

FUEL PUMP

CLAMPS

The arrow marks indicate the fuel flow direction.

and install the fuel inlet cap (see page 23).

4. Remove the engine cover (see page

31), and remove the fuel filter.

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

5. Install the new fuel filter so that the arrow mark on the fuel filter is toward the fuel pump side.

Fuel flow will be impeded if the filter is installed backward.

6. Connect the fuel tubes to the fuel filter securely with the tube clamps.

7. Remove the clamps used to close the fuel tubes.

8. Prime fuel to the fuel filter.

(When using the internal fuel tank)

Pull the starter grip to prime the carburetor with gasoline (see page

39) and check for leaks.

(When using the portable fuel tank)

Connect the fuel line and pump the primer bulb (see page 40) and check for leaks.

9. If loss of power or hard starting is found caused by excessive water or sediment accumulated in the fuel filter, inspect the fuel tank. Clean the fuel tank if necessary.

10.Install the engine cover (see page

31).

32ZVC6000.book Page 85 Thursday, April 28, 2016 10:51 AM

Fuel Tank Cleaning and Tank Filter Cleaning (Portable Fuel Tank)

(Optional equipment for BF5D and BF6A)

MAINTENANCE

Clean the fuel tank and tank filter every year or after every 200 operating hours.

<Fuel Tank Cleaning>

1. Disconnect the fuel line connector from fuel tank.

2. Empty the tank, pour in a small quantity of gasoline, and clean the tank thoroughly by shaking it.

Drain and dispose of the gasoline properly.

FUEL LINE

FUEL LINE CONNECTOR

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MAINTENANCE

<Tank Filter Cleaning>

5 mm SCREWS

CONNECTOR

GASKET

Replacing the Fuse (Equipped type)

The fuse is attached to the battery charge cable.

SPARE FUSE

FUSE

BLOWN FUSE

FUEL TANK FILTER

FUEL TANK FILTER JOINT

(Fuel Line Connector)

1. Remove the four 5 mm screws using a flat screwdriver, then remove the fuel line connector and fuel tank filter from the tank.

2. Clean the filter in nonflammable solvent. Inspect the fuel tank filter and the connector gasket. Replace them if damaged.

3. Reinstall the filter and line connector in the fuel tank. Tighten the four 5 mm screws securely.

86

FUSE CASE LID

If the fuse blows, running the engine will not charge the battery. Before replacing the fuse, check the current ratings of the electrical accessories and ensure that there are no abnormalities.

<How to replace the fuse>

1. Stop the engine.

2. Remove the fuse case lid and pull the blown fuse out of the clip with your finger.

3. Push the spare fuse into the clips.

<Designated fuse> 15A

Never use a fuse with a different rating from that specified. Serious damage to the electrical system or a fire may result.

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.

32ZVC6000.book Page 87 Thursday, April 28, 2016 10:51 AM

MAINTENANCE

Propeller and Shear Pin Change

COTTER PIN

SPARE SHEAR PIN

PROPELLER

CAP

SHEAR PIN

A shear pin is used to protect the propeller and drive mechanism from damage when the propeller strikes an obstruction.

If the propeller is damaged by striking a rock, or other obstacle, replace the propeller.

PROPELLER

• When replacing, remove the emergency stop switch clip to prevent an accidental startup of the engine.

• The propeller is thin and sharp.

To protect your hands, wear the heavy gloves during replacement.

Replacement

1. Remove the cotter pin, the propeller cap and the propeller.

SPARE COTTER PIN

2. Remove the broken shear pin and replace it with a new one.

3. Install the propeller or install a new propeller if the propeller is damaged, then install the propeller cap finger tight.

4. Install a new cotter pin, and spread the ends of it as shown.

Use a Honda Genuine shear pin and cotter pin.

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MAINTENANCE

Servicing a Submerged Outboard

Motor

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

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

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

2. Drain the fuel tank into a suitable container.

3. Loosen the carburetor drain screw, drain the contents of the carburetor into a suitable container, then retighten the drain screw (see page

90).

STARTER ROPE

4. Remove the spark plug.

Disengage the emergency stop switch clip from the emergency stop switch and pull the starter grip several times to completely expel water from the cylinder.

• When cranking the engine with an open ignition circuit (spark plug removed from the ignition circuit), disengage the emergency stop switch clip to prevent electrical damage to the ignition system.

88

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

32ZVC6000.book Page 89 Thursday, April 28, 2016 10:51 AM the emergency stop switch clip with the emergency stop switch.

7. Attempt to start the engine.

5. Change the engine oil (see page

74). If there was water in the engine crankcase, or if the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for 1/2 hour.

6. Pour a teaspoon (5 - 10 cm

3

) of engine oil into the spark plug hole, then pull the starter grip several times to lubricate the inside of the cylinder.

Reinstall the spark plug and engage

Exposed moving parts can cause injury. Use extreme care when installing the engine cover. Do not operate the outboard motor without the engine cover.

• If the engine fails to start, remove the spark plug, clean and dry the electrode, then reinstall the spark plug and attempt to start the engine again.

• If the engine starts, and no mechanical damage is evident, continue to run the engine for 1/2 hour or longer (be sure the water level is at least 100 mm (4 in) above the antiventilation plate).

8. As soon as possible, take the outboard motor to a Honda outboard motor dealer for inspection and service.

MAINTENANCE

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13. STORAGE

For longer service life of the outboard motor, have your outboard motor serviced by an authorized Honda outboard motor dealer before storage.

However, the following procedures can be performed by you, the owner, with a minimum of tools.

Fuel

Gasoline spoils very quickly depending on factors such as light exposure, temperature and time.

In worst cases, gasoline can be contaminated within 30 days.

Using contaminated gasoline can seriously damage the engine

(carburetor clogged, valve stuck).

Such damage due to spoiled fuel is disallowed from coverage by the warranty.

To avoid this please strictly follow these recommendations:

• Only use specified gasoline (see page 34,35).

• Use fresh and clean gasoline.

• To slow deterioration, keep gasoline in a certified fuel container.

• If long storage (more than 30 days) is foreseen, drain the internal and portable fuel tanks and carburetor.

Draining the Gasoline

Gasoline is extremely flammable, and gasoline 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.

• Be careful not to spill fuel.

Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before storing or transporting the outboard motor.

• Do not smoke or allow flames or sparks where fuel is drained or stored.

Close the internal fuel tank vent by turning the vent knob clockwise all the way. If you will be storing, tilting or transporting the outboard motor.

1. When using the portable fuel tank

(BF5D and BF6A), disconnect the fuel line connector from the outboard motor.

Remove the portable fuel filler cap

(see page 35), drain the gasoline from the portable fuel tank into a suitable container, close the portable fuel tank vent by turning the vent knob clockwise all the way

(see page 22) and install the fuel inlet cap (see page 23).

2. Remove the internal fuel filler cap

(see page 34), and drain the gasoline from the internal fuel tank into a suitable container.

Install the internal fuel filler cap.

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3. Turn the fuel valve lever to the ON position (BF4A) or internal fuel tank position (BF5D and BF6A), and turn the internal fuel tank vent knob counterclockwise (see page

23).

4. Remove the engine cover (see page

31).

5. Disconnect the drain tube from the air guide, then connect it to the carburetor drain port as shown.

CARBURETOR

DRAIN SCREW

CARBURETOR

DRAIN PORT

AIR GUIDE

DRAIN

TUBE

6. Loosen the carburetor drain screw, and drain the gasoline into a suitable container.

7. After draining thoroughly, tighten the drain screws securely. Be sure to drain thoroughly as the gasoline deteriorates as time goes by.

8. Reconnect the drain tube to the air guide.

9. Turn the internal fuel tank vent knob clockwise all the way (see page 23).

Turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A).

10.Install the engine cover (see page

31).

(When using the internal fuel tank)

When starting the engine after draining the gasoline, prime the carburetor with gasoline (see page

39).

STORAGE

Outboard Motor Storage

1. Tilt the outboard motor, remove the engine cover and plug cap, pull the starter grip several times and completely drain off the cooling water.

• If the outboard motor is put on its side without completely draining off the cooling water immediately after stopping it, water may enter the engine from the exhaust port. Be sure, therefore, to drain off the cooling water before putting the outboard motor on its side.

• When pulling the starter grip, be careful not to touch the spark plug wire.

Before storing the outboard motor for a prolonged period, we recommend that you remove the fuel line connector and operate the engine at 2,000 to

3,000 min -1 (rpm) until it stops.

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STORAGE

2. Change the engine oil.

3. Remove the spark plug, and pour about a tablespoon (5 - 10 cm 3 ) of clean engine oil into the cylinder.

Crank the engine several revolutions to distribute the oil, then reinstall the spark plug and plug cap.

4. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are close.

Storing the engine in this position will help to protect it from internal corrosion.

5. Store the outboard motor in a clean and dry area.

Before storing, clean, flush and lubricate the outboard motor as described on pages 68, 69 and 82.

Battery Storage

Battery handling differs according to the type of the battery. Refer to the battery manufacturer’s instructions.

Batteries produce explosive gases:

If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

• CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid.

Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.

• Keep flames and sparks away, and do not smoke in the area.

ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

• POISON: Electrolyte is poison.

ANTIDOTE

─ External: Flush thoroughly with water.

─ Internal: Drink large quantities of water or milk.

Follow with milk of magnesia or vegetable oil, and call a physician immediately.

• KEEP OUT OF REACH OF

CHILDREN.

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(–) TERMINAL

(+) TERMINAL

RED

TERMINAL

COVER

BLACK TERMINAL COVER

1. Disconnect the battery cable at the battery negative (–) terminal, then at the battery positive (+) terminal.

2. Remove the battery and clean the battery terminals and battery cable terminals with a wire brush or sand paper.

Clean the battery with a solution of baking soda and warm water, taking care not to get the solution of water in the battery cells. Dry the battery thoroughly.

3. Fill the battery with distilled water to the upper level line. Never overfill the battery.

4. Store the battery on a level surface in a cool, dry, well ventilated place out of direct sunlight.

5. Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life.

STORAGE

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STORAGE

Storage Position of the Outboard

Motor

Store the outboard motor either vertically or horizontally as follows with the tiller handle raised.

Vertical storage

Horizontal storage

INCORRECT

1. Attach the stern brackets to a motor stand and mount the outboard motor to the brackets. (page 27).

2. Store the outboard motor with the tiller handle raised.

CASE PROTECTORS

Rest the outboard motor on the case protectors.

(With tiller handle side of the outboard motor upward)

Any other transport or storage position may cause damage or oil leakage.

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To protect the environment, do not dispose of this product, battery, engine oil, etc. carelessly by leaving them in the waste. Observe the local laws and regulations or consult your dealer for disposal.

14. DISPOSAL

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15. TROUBLESHOOTING

<Engine fails to start>

1. Emergency stop switch clip is not engaged.

2. Starter grip cannot be operated.

3. Out of fuel.

4. Fuel line is flattened or kinked.

5. Fuel connectors are not

Engage the emergency stop switch clip in place.

(page 43)

Set the shift lever in

NEUTRAL position.

(page 45)

Supply fuel. (page 34,35)

Check for bent or pinched fuel line.

Connect properly.

connected properly.

(When using the portable fuel

(pages 41,42) tank.)

6. Fuel filler cap vent knob is not turned ON.

7. Fuel system is not primed by squeezing the primer bulb.

(When using the portable fuel tank.)

8. Fuel is not reaching the carburetor.

Open the fuel filler cap vent knob. (page 22,23)

Squeeze the primer bulb to supply fuel.

(page 42)

Loosen the carburetor drain screw to see if there is fuel in the carburetor float bowl.

(page 90)

96

9. Engine is flooded.

10. Plug cap is not installed properly.

11. Fuel valve lever is not turned to the appropriate position.

Clean and dry the spark plug. (page 78)

Install plug cap securely.

(page 79)

Turn the fuel valve lever to the appropriate position. (page 15)

<Engine speed fluctuates or engine stalls>

1. Fuel level is low.

2. Fuel line is flattened or kinked.

(When using the portable fuel

Add fuel. (page 34,35)

Check for excessively bent or pinched fuel line.

tank.)

3. Fuel filter is clogged.

4. Spark plug is fouled.

5. Spark plug heat range is incorrect.

6. Spark plug gap is incorrect.

Replace fuel filter.

(page 83)

Remove spark plug and dry and clean it.

(page 78)

Replace with spark plug of proper heat range.

(page 78)

Adjust to proper gap.

(page 78)

32ZVC6000.book Page 97 Thursday, April 28, 2016 10:51 AM

<Engine speed does not increase>

1. Fuel line is flattened or kinked.

(When using the portable fuel tank.)

2. Fuel filter is clogged.

Check for excessively bent or pinched fuel line.

3. Engine oil level is low.

4. Unmatched propeller is selected.

5. Passengers are not distributed equally.

6. Outboard motor is not installed properly.

Replace fuel filter.

(page 83)

Check engine oil and add to specified level.

(page 32)

Consult with an authorized Honda outboard motor dealer.

Distribute the passengers equally.

Install the outboard motor in the proper position. (page 25 to 28)

TROUBLESHOOTING

<Engine overheats>

1. Water intake and/or water check tube are/is clogged.

2. Engine is overloaded because of unequally distributed passengers or excessive load on the boat.

3. Thermostat is faulty.

Clean water intake and/ or water check tube.

Distribute the passengers equally. Do not load on the boat excessively.

4. Cavitation.

Consult with an authorized Honda outboard motor dealer.

Install the outboard motor in the proper position. (page 25 to 28)

<Engine overrevs>

1. Cavitation.

2. Propeller is damaged.

3. Unmatched propeller is selected.

Install the outboard motor in the proper position. (page 25 to 28)

Replace propeller.

(page 87)

Consult with an authorized Honda outboard motor dealer.

4. Trim angle is not correct. Trim to correct angle.

(page 27)

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16. SPECIFICATIONS

MODEL

Description

Code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

(weight) *1

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

434 mm (17.1 in)

27 kg (60 lbs)

*1 With propeller

*2 Optional Equipment

*3 For U types

*4 For D types

BF4A

BACC

SHND SHNU LHND

524 mm (20.6 in)

LHNU

347 mm (13.7 in)

1,020 mm (40.2 in) 1,147 mm (45.2 in)

561 mm (22.1 in)

27.5 kg (60.6 lbs)

2.9 kW (4 PS)

4,500 – 5,500 min -1 (rpm)

4-stroke, single cylinder, OHV type

127 cm 3 (7.7 cu-in)

0.6 – 0.7 mm (0.024 – 0.028 in)

Recoil starter

C.D.I.

Lubrication system

Specified oil

Oil capacity

D.C. output *2

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Tank capacity

Gear change

Steering equipment

Steering angle

Transom angle

Tilt up angle

(when transom angle at 12°)

Standard propeller

(No. of blades –

diameter × pitch)

Trochoid pump pressure lubrication

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

Gear case: API standard (GL-4) SAE 90

Hypoid gear oil

Engine: 0.55 L (0.58 US qt, 0.48 Imp qt)

Gear case: 0.10 L (0.11 US qt, 0.09 Imp qt)

12V – 6A

Water cooling with thermostat

Underwater exhaust

BKR6E-E (NGK)

Mechanical type

Unleaded gasoline

(91 research octane, 86 pump octane or higher)

Internal fuel tank: 1.5 L (0.40 US gal, 0.33 Imp gal)

Forward – Neutral – Reverse (dog type)

Bar handle

45° (right and left)

5 stages (4°, 8°, 12°, 16°, 20°)

3 stages adjustment (18°, 34° and 58°)

3 – 200 × 170 mm (3 – 7-7/8 × 6-3/4 in)*3

3 – 200 × 190 mm (3 – 7-7/8 × 7-1/2 in)*4

Honda outboards are power rated in accordance with ISO8665 (propeller shaft output).

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MODEL

Description

Code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

(weight) *1

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

BF5D

BADC

SHD SHU SHND SHNU LHD LHU LHND LHNU

524 mm (20.6 in)

347 mm (13.7 in)

1,020 mm (40.2 in) 1,147 mm (45.2 in)

434 mm (17.1 in) 561 mm (22.1 in)

27.8 kg

(61.3bs)

27 kg

(60 lbs)

28.3 kg

(62.4 lbs)

3.68 kW (5 PS)*3

3.7 kW (5 PS)*4

4,500 – 5,500 min -1 (rpm)

4-stroke, single cylinder, OHV type

127 cm 3 (7.7 cu-in)

0.6 – 0.7 mm (0.024 – 0.028 in)

Recoil starter

C.D.I.

27.5 kg

(60.6 lbs)

*1 With propeller

*2 SHND, SHNU, LHND, and LHNU types are Optional

Equipment

*3 For U types

*4 For D types

Lubrication system

Specified oil

Oil capacity

D.C. output *2

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Tank capacity

Gear change

Steering equipment

Steering angle

Transom angle

Tilt up angle

(when transom angle at 12°)

Standard propeller

(No. of blades –

diameter × pitch)

SPECIFICATIONS

Trochoid pump pressure lubrication

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

Gear case: API standard (GL-4) SAE 90

Hypoid gear oil

Engine: 0.55 L (0.58 US qt, 0.48 Imp qt)

Gear case: 0.10 L (0.11 US qt, 0.09 Imp qt)

12V – 6A

Water cooling with thermostat

Underwater exhaust

BKR6E-E (NGK)

Mechanical type

Unleaded gasoline

(91 research octane, 86 pump octane or higher)

Internal fuel tank: 1.5 L (0.40 US gal, 0.33 Imp gal)

Portable fuel tank: 12 L (3.2 US gal, 2.6 Imp gal)

Forward – Neutral – Reverse (dog type)

Bar handle

45° (right and left)

5 stages (4°, 8°, 12°, 16°, 20°)

3 stages adjustment (18°, 34° and 58°)

3 – 200 × 170 mm (3 – 7-7/8 × 6-3/4 in)*3

3 – 200 × 190 mm (3 – 7-7/8 × 7-1/2 in)*4

Honda outboards are power rated in accordance with ISO8665 (propeller shaft output).

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SPECIFICATIONS

MODEL

Description

Code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

(weight) *1

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

BF6A

BAEC

SHD SHU SHND SHNU LHD LHU LHND LHNU

524 mm (20.6 in)

347 mm (13.7 in)

1,020 mm (40.2 in) 1,147 mm (45.2 in)

434 mm (17.1 in) 561 mm (22.1 in)

27.8 kg

(61.3 lbs)

27 kg

(60 lbs)

28.3 kg

(62.4 lbs)

4.4 kW (6 PS)

5,000 – 6,000 min -1 (rpm)

4-stroke, single cylinder, OHV type

127 cm 3 (7.7 cu-in)

0.6 – 0.7 mm (0.024 – 0.028 in)

Recoil starter

C.D.I.

27.5 kg

(60.6 lbs)

*1 With propeller

*2 SHND, SHNU, LHND, and LHNU types are Optional

Equipment

*3 For U types

*4 For D types

Lubrication system

Specified oil

Oil capacity

D.C. output *2

Cooling system

Exhaust system

Spark plug

Fuel pump

Fuel

Tank capacity

Gear change

Steering equipment

Steering angle

Transom angle

Tilt up angle

(when transom angle at 12°)

Standard propeller

(No. of blades –

diameter × pitch)

Trochoid pump pressure lubrication

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

Gear case: API standard (GL-4) SAE 90

Hypoid gear oil

Engine: 0.55 L (0.58 US qt, 0.48 Imp qt)

Gear case: 0.10 L (0.11 US qt, 0.09 Imp qt)

12V – 6A

Water cooling with thermostat

Underwater exhaust

BKR6E-E (NGK)

Mechanical type

Unleaded gasoline

(91 research octane, 86 pump octane or higher)

Internal fuel tank: 1.5 L (0.40 US gal, 0.33 Imp gal)

Portable fuel tank: 12 L (3.2 US gal, 2.6 Imp gal)

Forward – Neutral – Reverse (dog type)

Bar handle

45° (right and left)

5 stages (4°, 8°, 12°, 16°, 20°)

3 stages adjustment (18°, 34° and 58°)

3 – 200 × 170 mm (3 – 7-7/8 × 6-3/4 in)*3

3 – 200 × 190 mm (3 – 7-7/8 × 7-1/2 in)*4

Honda outboards are power rated in accordance with ISO8665 (propeller shaft output).

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SPECIFICATIONS

Noise and Vibration

[U type]

MODEL

CONTROL SYSTEM

Sound Pressure level at operator’s ears

(2006/42/EC, ICOMIA 39-94)

Uncertainty

(2006/42/EC, ICOMIA 39-94)

Measured sound power level

(Reference to EN ISO3744)

Uncertainty

(Reference to EN ISO3744)

Vibration level at hand arm

(2006/42/EC, ICOMIA 38-94)

Uncertainty

(2006/42/EC, ICOMIA 38-94)

BF4A

T (Tiller handle)

75 dB (A)

2 dB (A)

–

–

2.8 m/s 2

0.4 m/s 2

BF5D

T (Tiller handle)

77 dB (A)

2 dB (A)

–

–

3.0 m/s 2

0.5 m/s 2

BF6A

T (Tiller handle)

79 dB (A)

3 dB (A)

–

–

3.1 m/s 2

0.4 m/s 2

Reference to: ICOMIA Standard: as it specifies the engine operating conditions and measurement conditions.

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17. MAJOR Honda DISTRIBUTOR ADDRESSES

For further information, please contact Honda Customer Information Centre at the following address or telephone number:

For European

AUSTRIA

Honda Austria GmbH

Hondastraße 1

2351 Wiener Neudorf

Tel. : +43 (0)2236 690 0

Fax : +43 (0)2236 690 480 http://www.honda.at

[email protected]

BULGARIA

Kirov Ltd.

49 Tsaritsa Yoana Blvd

1324 Sofia

Tel. : +359 2 93 30 892

Fax : +359 2 93 30 814 www.kirov.net

[email protected]

CZECH REPUBLIC

BG Technik cs, a.s.

U Zavodiste 251/8

15900 Prague 5 - Velka Chuchle

Tel. : +420 2 838 70 850

Fax : +420 2 667 111 45 www.hondamarine.cz

FRANCE

Honda Motor Europe Ltd

Relation Clients Produits d'équipements

Parc d'activités de Pariest, Allée du 1er mai

Croissy Beaubourg BP46, 77312 Marne La

Vallée Cedex 2

Tél. : 01 60 37 30 00

Fax : 01 60 37 30 86 http://www.honda.fr

[email protected]

BALTIC STATES

(Estonia/Latvia/

Lithuania)

Honda Motor Europe Ltd

Tulika 15/17

10613 Tallinn

Tel. : +372 6801 300

Fax : +372 6801 301

[email protected].

CROATIA

Fred Bobek d.o.o.

Honda-Marine Croatia - Trg. - lnd.

zona bb

22211 Vodice

Tel. : +385 22 44 33 00/33 10

Fax : +385 22 44 05 00 www.honda-marine.hr

DENMARK

TIMA A/S

Tårnfalkevej 16

2650 Hvidovre

Tel. : +45 36 34 25 50

Fax : +45 36 77 16 30 http://www.hondapower.dk

GERMANY

Honda Deutschland GmbH

Sprendlinger Landstraße 166

63069 Offenbach am Main

Tel.: 01 80 5/20 20 90

Fax.: +49 69 8320 20 http://www.honda.de

[email protected]

BELGIUM

Honda Belgium

Doornveld 180-184

1731 Zellik

Tel. : +32 2620 10 00

Fax : +32 2620 10 01 http://www.honda.be

[email protected]

CYPRUS

Alexander Dimitriou & Sons Ltd.

162, Yiannos Kranidiotis

Avenue

2235 Latsia, Nicosia

Tel. : +357 22 715 300

Fax : +357 22 715 400

FINLAND

OY Brandt AB

Tuupakantie 7B

01740 Vantaa

Tel. : +358 207757200

Fax : +358 (0)9 878 5276 www.brandt.fi

GREECE

Saracakis Brothers S.A.

71, Leoforos Athinon

10173 Athens

Tel. : +30 210 3483582

Fax : +30 210 3418092 http://www.honda.gr

[email protected]

102

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MAJOR Honda DISTRIBUTOR ADDRESSES

For further information, please contact Honda Customer Information Centre at the following address or telephone number:

For European (continued)

HUNGARY

Motor Pedo Co., Ltd.

Kamaraerdei ut 3.

2040 Budaors

Tel. : +36 23 444 971

Fax : +36 23 444 972 http://www.hondakisgepek.hu

[email protected]

ITALY

Honda Italia Industriale S.p.A.

Via della Cecchignola, 13

00143 Roma

Tel. : +848 846 632

Fax : +39 065 4928 400 www.hondaitalia.com

[email protected]

NORWAY

AS Kellox

Boks 170 - Nygårdsveien 67

1401 Ski

Tel. : +47 64 97 61 00

Fax : +47 64 97 61 92 www.kellox.no

ICELAND

Bernhard ehf.

Vatnagardar 24-26

104 Reykdjavik

Tel. : +354 520 1100

Fax : +354 520 1101 www.honda.is

IRELAND

Two Wheels ltd

M50 Business Park, Ballymount

Dublin 12

Tel. : +353 1 4381900

Fax : +353 1 4607851 http://www.hondaireland.ie

[email protected]

MALTA

Associated Motors Company Ltd.

New Street in San Gwakkin Road -

Mriehel Bypass

Mriehel QRM17

Tel. : +356 21 498 561

Fax : +356 21 480 150

NETHERLANDS

Honda Nederand B.V.

Afd, Power Equipment

Capronilaan 1

1119 NN Schiphol-Rijk

Tel. : +31 20 7070000

Fax : +31 20 7070001 http://www.honda.nl

POLAND

Aries Power Equipment Sp. z o.o.

ul. Wroclawska 25

01-493 Warszawa

Tel. : +48 (22) 861 43 01

Fax : +48 (22) 861 43 02 www.ariespower.pl

www.mojahonda.pl

[email protected]

PORTUGAL

Honda Motor Europe Ltd

Rua Fontes Pereira de Melo 16

Abrunheira, 2714-506 Sintra

Tel. : +351 21 915 53 00

Fax : +351 21 915 88 87 http://www.honda.pt

honda.produtos@honda-eu.

com

REPUBLIC OF

BELARUS

Scanlink Ltd.

Kozlova Drive, 9

220037 Minsk

Tel. : +375 172 999090

Fax : +375 172 999900 http://www.hondapower.by

ROMANIA

Hit Power Motor Srl str. Vasile Stroescu nr. 12, Camera 6,

Sector 2

021374 Bucuresti

Tel. : +40 21 637 04 58

Fax : +40 21 637 04 78 http://www.honda.ro

[email protected]

RUSSIA

Honda Motor RUS LLC

1, Pridirizhnaya Street,

Sharapovo settlement,

Naro-Fominsky district, Moscow Region,

143350 Russia

Tel. : +7 (495) 745 20-80

Fax : +7 (495) 745 20 81 www.honda.co.ru

[email protected]

103

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MAJOR Honda DISTRIBUTOR ADDRESSES

For further information, please contact Honda Customer Information Centre at the following address or telephone number:

For European (continued)

SERBIA &

MONTENEGRO

Fred Bobek d.o.o.

Honda-Marine Croatia - Trg. - Ind.

zona bb 22211 Vodice

Tel. : +385 22 44 33 00/33 10

Fax : +385 22 44 05 00 www.honda-marine.hr

SLOVAK REPUBLIC

Honda Motor Europe Ltd

Prievozská 6 821 09 Bratislava

Tel. : +421 2 32131112

Fax : +421 2 32131111 http://www.honda.sk

SPAIN &

Las Palmas province

(Canary Islands)

Greens Power Products, S.L.

Poligono Industrial Congost -

Av Ramon Ciurans n°2

08530 La Garriga - Barcelona

Tel. : +34 93 860 50 25

Fax : +34 93 871 81 80 http://www.hondaencasa.com

Tenerife province

(Canary Islands)

Automocion Canarias, S.A.

Carretera General del Sur, KM. 8,8

38107 Santa Cruz de Tenerife

Tél. : +34 (922) 620 617

Fax : +34 (922) 618 042 www.aucasa.com

[email protected]

[email protected]

SWITZERLAND

Honda Motor Europe Ltd

10 Route des Moulières

1214 Vernier-Genève

Tel. : +41 (0)22 939 09 09

Fax : +41 (0)22 939 09 97 www.honda.ch

TURKEY

Anadolu Motor Uretim ve Pazarlama

AS

Esentepe mah. Anadolu cad. No: 5

Kartal 34870 Istanbul

Tel. : +90 216 389 59 60

Fax : +90 216 353 31 98 www.anadolumotor.com.tr

[email protected]

UNITED KINGDOM

Honda Motor Europe Ltd

470 London Road

Slough - Berkshire, SL3 8QY

Tel. : +44 (0)845 200 8000 http://www.honda.co.uk

For Australian

AUSTRALIA

Honda Australia Motorcycle and

Power Equipment Pty. Ltd

1954-1956 Hume Highway

Campbellfield Victoria 3061

Tel. : (03) 9270 1111

Fax : (03) 9270 1133 http://www.hondampe.com.au/

For Mexico

SLOVENIA

AS Domzale Moto Center D.O.O.

Blatnica 3A

1236 Trzin

Tel. : +386 1 562 22 62

Fax : +386 1 562 37 05 www.honda-as.com

[email protected]

SWEDEN

Honda Nordic AB

Box 31002-Långhusgatan 4

215 86 Malmö

Tel. : +46 (0)40 600 23 00

Fax : +46 (0)40 600 23 19 www.honda.se

[email protected]

UKRAINE

Honda Ukraine LLC

101 Volodymyrska Str. - Build. 2

Kyiv 01033

Tel. : +380 44 390 14 14

Fax : +380 44 390 14 10 http://www.honda.ua

[email protected]

MEXICO

Honda de Mexico, S.A. de C.V.

Carretera a el castillo No. 7250

El Salto , Jalisco C.P.45680

TEL:+52 33 32 84 00 00

FAX:+52 33 32 84 00 60 http://www.honda.com.mx

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18. ‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

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‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

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‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

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‘‘EC DECLARATION OF CONFORMITY’’ CONTENT OUTLINE

109

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19. INDEX

A

Adjusting Rod

Anode Metal

.......................................................... 22

............................................................ 20

B

Battery Charging DC Cable

Battery Connections

Battery Electrolyte Level

Battery Service

Battery Storage

Break-in Procedure

...................................... 30

................................................. 29

.......................................... 37

........................................................ 80

........................................................ 92

................................................... 54

C

CE mark location

Choke Knob ............................................................. 17

Clamp Screws

..................................................... 11

.......................................................... 23

Cleaning and Flushing

Cruising in Shallows

.............................................. 68

Component Identification

Controls

Cooling Water Check Hole

Cooling Water Intake Port

......................................... 12

................................................................... 14

....................................... 20

........................................ 21

................................................ 60

D

Disposal .................................................................. 95

Draining the Gasoline ............................................... 90

E

‘‘EC DECLARATION OF CONFORMITY’’ CONTENT

OUTLINE

Emergency

Starting

......................................................... 105

............................................................... 48

Stop Switch

Stop Switch Lanyard/Clip

Engine

Cover Lock Latch

Oil Change

Oil Level

......................................................... 18

..................................... 18

................................................ 21

.......................................................... 74

............................................................. 32

F

Filling the Carburetor with Gasoline

Fuel

Filler Cap Vent Knob ........................................... 23

Filler Cap Vent Knob/Fuel Gauge

Filter Check/Replacement

Fuel Valve Lever

......................... 22

..................................... 85

................................................. 15

Inlet Cap and Fuel Inlet

Level

........................................ 23

............................................................. 34

Line

Connection

Removal

Primer Bulb

.......................... 39

, 35

...................................................... 41

.......................................................... 63

......................................................... 18

110

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Storage ................................................................ 90

Tank and Tank Filter Cleaning

Tank and Vent Knob

.............................. 85

....................................... 22 , 23

G

Gasoline Containing Alcohol

Gear Oil Change

.................................... 36

...................................................... 76

H

Handle Stopper ........................................................ 16

High Altitude Operation ........................................... 60

I

Installation

Height

Location

............................................................... 25

................................................................. 26

.............................................................. 25

L

Lubrication .............................................................. 82

M

Maintenance

Schedule

............................................................ 70

.............................................................. 72

O

Oil Pressure Indicator Light

Operation

...................................... 19

................................................................. 54

INDEX

Other Checks

Angle

Attachment

Storage

........................................................... 38

Outboard Motor

.................................................................. 27

.......................................................... 27

................................................................ 91

Over-rev Limiter ...................................................... 59

P

Pre-Operation Checks .............................................. 31

Priming the Carburetor with Gasoline ........................ 39

R

Removing/Installing Engine Cover

Replacing the Fuse

............................ 31

................................................... 86

S

Safety ........................................................................ 6

Information

Starter Grip

............................................................ 6

Safety Label Locations

Shear Pin Change

Shift Lever

Spark Plug Service

Specifications

Starter Rope Check

............................................... 9

Servicing a Submerged Outboard Motor

..................................................... 87

.............................................................. 14

.......................................................... 98

............................................................. 14

Starting the Engine

.................... 88

................................................... 78

.................................................. 77

................................................... 39

Steering Friction Bolt ............................................... 21

111

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INDEX

Stopping the Engine

Storage

................................................. 61

.................................................................... 90

Position of the Outboard Motor ............................. 94

T

Throttle

Friction Knob

Grip

Tilt Lever

Trailering

Transom Height

Transporting

Troubleshooting

....................................................... 17

..................................................................... 17

................................................................ 20

Tilting the Outboard Motor

Tool Kit and Spare Parts

Starting Problems

....................................... 57

........................................... 71

................................................................. 67

....................................................... 25

............................................................ 63

....................................................... 96

................................................. 53

W

With Water Hose Joint ............................................. 68

Without Water Hose Joint ......................................... 69

112