Honda Marine BFP9.96D Owner's Manual

02/03/25 20:50:08 31ZW8A00_001

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

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

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

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

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

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

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer.

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

2002 Honda Motor Co., Ltd. All

Rights Reserved

INTRODUCTION

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INTRODUCTION

A FEW WORDS ABOUT

SAFETY

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

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

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

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

Safety Labels − on the outboard motor.

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

and one of

These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

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

Safety Headings − such as IMPORTANT SAFETY INFORMATION.

Safety Section − such as OUTBOARD MOTOR SAFETY.

Instructions − how to use this outboard motor correctly and safely.

This entire book is filled with important safety information − please read it carefully.

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

. 7

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

. 7

SAFETY LABEL LOCATIONS ................................

. 9

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

. 10

CONTROL AND FEATURE

IDENTIFICATION CODES ................................

. 10

COMPONENT AND CONTROL LOCATIONS ....

. 11

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

. 14

H Type (tiller handle)

Engine Stop Switch and Switch Clip ....................

. 14

Choke Knob (H type manual choke) ....................

. 14

Throttle Grip ..........................................................

. 15

Throttle Friction Dial

Gearshift Lever

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

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

. 15

. 15

Recoil Starter Grip ................................................

. 16

Electric Starter Button (models equipped with electric starter) ...........................................

. 16

R Type (remote control)

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

. 16

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

. 17

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

. 18

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

. 18

CONTENTS

Common Controls

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

. 20

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

. 20

Steering Friction Lever .........................................

. 21

Tilt Lever ...............................................................

. 21

INSTRUMENTS

Fuel Gauge

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

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

. 21

. 21

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

. 22

Oil Pressure Indicator (R type) (H type) ...............

. 22

Overheating Indicator (R type)

Cooling System Indicator

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

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

. 22

. 23

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

. 23

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

. 23

Automatic Choke (equipped type only) ................

. 23

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

. 23

Portable Fuel Tank ................................................

. 24

Fuel Cap Vent Knob

Fuel Priming Bulb

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

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

. 24

. 24

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CONTENTS

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

. 25

POWER REQUIREMENTS .....................................

. 25

BOAT TRANSOM REQUIREMENTS

INSTALLATION POSITION

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

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

. 25

. 26

ATTACHMENT .......................................................

. 26

TRANSOM ANGLE ADJUSTMENT .....................

. 27

BATTERY CONNECTIONS ...................................

. 27

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

. 30

ARE YOU READY TO GET UNDER WAY

IS YOUR OUTBOARD MOTOR

？ .....

. 30

READY TO GO ？ ................................................

. 30

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

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

. 32

. 32

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

. 32

TRANSOM ANGLE ADJUSTMENT .....................

. 33

PORTABLE FUEL TANK .......................................

. 34

FUEL HOSE CONNECTIONS ................................

. 34

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

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

. 35

. 35

H Type (tiller handle) ............................................

. 35

R Type (remote control) ........................................

. 38

EMERGENCY STARTING .....................................

. 40

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

. 43

Emergency Engine Stopping

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

. 43

GEARSHIFTING AND

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

. 43

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

. 45


. 45


. 46

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

. 47


. 47


. 47

CRUISING ................................................................

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

. 48

. 49

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

. 50

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CONTENTS

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

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

. 51

. 51

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

TOOL KIT AND EMERGENCY STARTER

. 52

ROPE .....................................................................

. 53

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

ENGINE COVER REMOVAL AND

. 54

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

. 56

Engine Oil Level Check

Engine Oil Change

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

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

. 56

. 57

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

. 58

Engine Oil Recommendations

Lubrication Points

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

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

. 59

. 60

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

. 61

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

. 63

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

. 64

Fuel Pump Filter Inspection and Replacement

Portable Fuel Tank and Filter Cleaning

.........

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

. 65

. 68

Recoil Starter Rope Inspection

Anode Replacement

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

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

. 69

. 69

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

. 70

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

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

. 71

. 71

Cleaning and Flushing

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

. 73

Engine Oil

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

. 71

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

. 75

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

. 75

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

. 76

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

WITH OUTBOARD MOTOR INSTALLED

. 77

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

. 77

WITH OUTBOARD MOTOR REMOVED

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

. 77

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CONTENTS

TAKING CARE OF UNEXPECTED

PROBLEMS ..........................................................

. 78

BATTERY WILL NOT CHARGE AND

OIL PRESSURE INDICATOR LIGHT GOES OFF

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

. 84

OVERHEATING INDICATOR LIGHT COMES

ON AND ENGINE SPEED IS LIMITED

(remote control type) .........................................

. 85

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

. 86

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

. 88

Serial Number locations ........................................

. 88

Carburetor Modification for High Altitude

Operation ...........................................................

. 89

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

. 89

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

. 90

Emission Control System Information

Star Label

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

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

. 91

. 93

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

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

. 95

. 97

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

. 98

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

. 101

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IMPORTANT SAFETY

INFORMATION

Honda BF8D/BFP8D/BF9.9D and

BFP9.9D outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

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

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

OUTBOARD MOTOR SAFETY

Operator Responsibility

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

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

Understand the use of all controls.

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

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

Attach the emergency stop switch lanyard securely to the operator.

Always wear a PFD (Personal

Flotation Device) while on the boat.

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

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

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

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

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Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode.

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

Remove any portable fuel tank from the boat for refueling. Keep the portable fuel tank away from the battery or other potential spark sources.

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

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

Carbon Monoxide Hazard

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

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SAFETY LABEL LOCATIONS


The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized Honda

Marine servicing dealer for a replacement.

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CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model BF8D / BF9.9D

Type

Shaft Length

Tiller Handle

Remote Control

Electric Starter

Power Thrust Propeller

Battery Charging DC Receptacle

BFP8D / BFP9.9D

SHA LHA SHSA LHSA SRA LRA LHA XHA LHSA XHSA LRA XRA

S

H

L

H

S

H

L

H

S L L

H

X

H

L

H

X

H

L X

S S

R

S

R

S

P P

S

P

S

P

R

S

P

R

S

P

10

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

BF8D/BF9.9D/BFP8D/BFP9.9D are provided with the following types according to the shaft length, control system, and start system.

According to Shaft Length

S: Short Shaft

L: Long Shaft

X: Extra Long Shaft

According to Control System

H: Tiller Handle Control

R: Remote Control

L

(Example)

H S A

Destination

A=United States

S=Electric Starter

R=Remote Control

H=Tiller Handle

S=Short Shaft

L=Long Shaft

X=Extra Long Shaft

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COMPONENT AND CONTROL LOCATIONS

H Type (tiller handle)

STARTER GRIP

OIL FILLER CAP

SHIFT LEVER

TILLER

HANDLE

ELECTRIC STARTER

BUTTON

(Electric starter type only)

ENGINE COVER

CHOKE KNOB

(Equipped type only)

OIL PRESSURE

INDICATOR LIGHT

FUEL HOSE

CONNECTOR

SWITCH CLIP

THROTTLE

FRICTION

DIAL

OIL LEVEL

DIPSTICK

STERN

BRACKET

COOLING

SYSTEM

INDICATOR

ENGINE OIL

DRAIN SCREW

CLAMP SCREW

TILT LEVER

ADJUSTING

ROD

GEAR OIL

CHECK BOLT

WATER HOSE

JOINT HOLE

(Inside engine cover)

ANTIVENTILATION

PLATE

THROTTLE

GRIP

ENGINE STOP

SWITCH

LANYARD

COOLING WATER

INTAKE PORT

EXHAUST PORT

GEAR OIL

DRAIN BOLT PROPELLER

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R Type (remote control)

OIL FILLER CAP

OIL LEVEL

DIPSTICK

COOLING

SYSTEM

INDICATOR

ENGINE OIL

DRAIN SCREW

STARTER GRIP

TILT

ENGINE COVER

LEVER

STERN

BRACKET

CLAMP SCREW

ADJUSTING

ROD

WATER HOSE

JOINT HOLE

(Inside engine cover)

GEARSHIFT/THROTTLE

CONTROL LEVER

NEUTRAL RELEASE

LEVER

OIL PRESSURE

INDICATOR LIGHT

OVERHEATING

INDICATOR LIGHT

FAST IDLE

LEVER

BUZZER

(inside box)

REMOTE CONTROL

FRICTION ADJUSTER

IGNITION

SWITCH

GEAR OIL

CHECK BOLT

ANTIVENTILATION

PLATE

LANYARD

EMERGENCY

STOP SWITCH

COOLING WATER

INTAKE PORT

EXHAUST PORT SWITCH CLIP

GEAR OIL

DRAIN BOLT PROPELLER

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FUEL GAUGE VENT KNOB

FUEL CAP

PRIMING BULB

FUEL TANK

FUEL HOSE

FUEL HOSE CONNECTOR

(FEMALE)

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CONTROLS


Engine Stop Switch and Switch

Clip

ENGINE STOP

SWITCH

LANYARD

The engine stop switch has controls for normal engine stopping and emergency engine stopping.

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

Device) or worn around the wrist as shown.

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

A spare switch clip is supplied with the tool kit.

SWITCH CLIP

Choke Knob (H type manual choke)

CHOKE KNOB

The choke knob opens and closes the choke valves in the carburetors.

The CLOSED position enriches the fuel mixture for starting a cold engine.

The OPEN position provides the correct fuel mixture for operation after starting, and for restarting a warm engine.

LANYARD

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Throttle Grip

THROTTLE INDEX

MARK

Throttle Friction Dial

FIX

THROTTLE

FRICTION DIAL


Gearshif t Lever

R (reverse)

N (neutral)

F (forward)

RELEASE

THROTTLE GRIP THROTTLE GRIP

The throttle grip controls engine speed.

An index mark on the tiller arm shows throttle position and is helpful for setting the throttle correctly when

starting (p.

36 ).

The throttle friction dial adjusts resistance to throttle grip rotation.

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

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

The gearshift lever is used to select F

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

The engine can be started with the gearshift lever in the N (neutral) position only.

If the gearshift lever is in the F

(forward) or R (reverse) position, the recoil starter will not operate, and the electric starter button (applicable models) will not operate the starter motor.

15

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Recoil Starter Grip

STARTER GRIP

Electric Starter Button (models equipped with electric starter)

R Type (remote control)

For panel-mount or top-mount remote control information, refer to the instructions provided with the remote control equipment.

Ignition Switch (side-mount type)

Pull the starter grip to operate the recoil starter for starting the engine manually.

The recoil starter will operate only

when the gearshift lever (p.

15 ) is in

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


BUTTON

Press the starter button to operate the electric starter for starting the engine.

The electric starter button can be used to operate the starter motor only

when the gearshift lever (p.

15 ) is in

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

IGNITION

SWITCH

O F F

O N

S T A R T

EMERGENCY

STOP SWITCH

CLIP

The ignition switch controls the ignition system and starter motor.

16

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Turning the ignition switch key to the

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

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

the gearshift lever (p.

15 ) is in the N

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

Turning the ignition switch to the

OFF position stops the engine.

Switch Clip and Emergency Stop

Switch (side-mount type)

EMERGENCY

STOP SWITCH

LANYARD

SWITCH CLIP

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

Device) or worn around the wrist as shown.

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

A spare switch clip is stored in a slot in the control housing.

SWITCH CLIP

LANYARD

SPARE SWITCH CLIP

17

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Fast Idle Lever

(side-mount type)

MAXIMUM FAST IDLE

Gearshif t/Throttle Control

Lever (side-mount type)


CONTROL LEVER

LOWEST POSITION

The fast idle lever is provided with the engine idle speed adjusting function.

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

18

FAST IDLE LEVER

Leave the fast idle lever in the lowest position to provide a rich fuel mixture for starting a cold engine.

Lift the fast idle lever to warm up a cold engine after starting and to start a warm engine.

NEUTRAL

RELEASE LEVER

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

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

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

Moving the control lever 30° from N

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

A friction adjuster near the base of the control lever adjusts the operating

resistance of the control lever (p.

46 ).

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


CONTROL LEVER

N (neutral)

F (forward) R (reverse)

E N G I N E

S P E E D

E N G I N E

S P E E D

HIGH

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Common Controls

Engine Cover Latch

Transom Angle Adjusting Rod

The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered.

(R type / XH type)

(SH / LH type)

ENGINE COVER

LATCH

ADJUSTING ROD

Proper adjustment prevents the outboard motor from being trimmed

too low (p.

48 ).

ADJUSTING ROD

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

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Steering Friction Lever Tilt Lever

TILT LEVER


INSTRUMENTS

Fuel Gauge

F R E E

L O C K

STEERING FRICTION LEVER

The steering friction lever adjusts steering resistance.

Less friction allows the outboard motor to turn more easily. More friction helps to hold steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.

T I L T

R U N

( L O C K )

The tilt lever enables the outboard motor to be raised for shallow water operation, beaching, launching, or mooring.

To tilt, move the lever to the TILT position, then raise the outboard motor until the tilt mechanism

engages at 30°, 45°, or 71° (p.

49 ).

FUEL GAUGE

A fuel gauge is built into the cap of the portable fuel tank.

21

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INDICATORS

Oil Pressure Indicator

(R type)

(H type)

(GREEN)

When the green light is lit, oil pressure is OK.

If oil pressure becomes low, the green light will go off, and the engine protection system will limit engine speed.

Remote controls are also equipped with a buzzer that sounds when the green light goes off.

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

Overheating Indicator

(R type)

(RED)

If the engine overheats, the red light will come on, and the engine protection system will limit engine speed.

Remote controls are also equipped with a buzzer that sounds when the red light comes on.

Engine overheating may be the result of clogged water intakes.

OIL PRESSURE INDICATOR LIGHT

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Cooling System Indicator

COOLING SYSTEM INDICATOR

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

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


OTHER FEATURES

Overrev Limiter

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

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

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

Automatic Choke (R type/HS type)

The engine is equipped with an automatic choke so that the choke system operation is not needed when starting the engine.

Anodes

ANODES

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

There are two anodes on the gear case.

23

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Portable Fuel Tank Fuel Cap Vent Knob Fuel Priming Bulb

VENT KNOB

CLOSE

OUTLET END

(MOTOR)

PRIMING BULB

O P E N

The portable fuel tank has a capacity of 3.2

US gal ( 12 ) and has a fuel gauge built into the cap.

INLET END

(TANK)

The cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat.

Open the vent knob 2 or 3 turns

before starting the engine (p.

34 ).

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

Before starting the engine, squeeze the priming bulb until it feels firm.

This will ensure that fuel is supplied

to the engine (p.

35 ).

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Correct and secure installation is essential for safe boating and good performance. Follow the installation instructions provided in this manual.

POWER REQUIREMENTS

Before installation, check to be sure that the outboard motor does not exceed the recommended maximum horsepower for the boat on which it is to be installed. Refer to the boat’s certification plate for recommended maximum horsepower. If the certification plate information is not available, contact the boat dealer or manufacturer.

For most applications, the outboard motor should have a horsepower rating which provides 80% of the maximum recommended horsepower for the boat.

BOAT TRANSOM

REQUIREMENTS


BFP9.9D outboard motors can be installed on a boat transom having a thickness range of 1.3

− 2.2 inches

(35 − 57 mm).

INSTALLATION POSITION

CENTER LINE

Install the outboard motor on the center of the boat transom.

INSTALLATION

The antiventilation plate of the outboard motor should be 0 − 2.0

inches below the bottom of the boat.

With the boat in the water and loaded, the antiventilation plate should be about 3.9 inches below the surface of the water.

T R A N S O M H E I G H T

Type:

S:

L:

X:

0

(0

−

−

50 mm

2.0 in)

Transom Height

17.0 in (433 mm)

22.2 in (563 mm)

27.7 in (703 mm)

25

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INSTALLATION

If the outboard motor is installed too low, the boat will squat and be hard to plane, it will tend to porpoise, and high-speed stability will be reduced.

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

Optimum installation height varies with boat type and bottom shape.

Contact the boat manufacturer for any special recommendations that are unique to a specific model of boat.

If the transom needs to be modified to accommodate the outboard motor, contact the boat manufacturer and follow their recommendations for corrective action.

ATTACHMENT

WASHER

BOLT

CLAMP SCREW

LOCK NUT

Attach the stern bracket to the boat transom by tightening the clamp screws.

Attach a rope from the boat to the hole in the stern bracket. This will help to prevent accidental loss of the outboard motor.

You may further secure the outboard motor by bolting the stern bracket to the boat transom. Use the optional mounting bolt and nut kit or other good quality stainless steel bolts, nuts, and washers. Apply silicone sealant to the bolt holes.

MOUNTING HOLE

WASHER

TRANSOM

BOARD

26

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TRANSOM ANGLE

ADJUSTMENT

Use the transom angle adjustment rod

(p.

33 ) to adjust the angle of the

outboard motor so the propeller is perpendicular to the surface of the water.

BATTERY CONNECTIONS

− TO ACCESSORIES

BATTERY


BFP9.9D outboard motors produce a

12-volt, 12-ampere battery-charging current and are equipped for connection to a 12-volt battery. The battery-charging circuit is protected by a 20-ampere fuse located in the engine compartment.

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

Lights and electrical accessories for the boat should be connected to the battery.

INSTALLATION

The battery should be kept in a corrosion-resistant battery box that is securely mounted in a location away from the fuel tank and protected from water and direct sunlight.

Types With Electric Starter

These types are equipped with battery cables. The positive (+) cable has a red band at the battery connector. The negative (-) cable has a black band at the battery connector.

For electric starter operation, use a

12-volt battery with an ampere-hour rating of at least 35 Ah.

Types Without Electric Starter

These types are equipped with a 12volt dc battery-charging receptacle which can be wired to a 12-volt battery to power lights and electrical accessories for the boat.

27

02/03/25 20:55:06 31ZW8A00_029

INSTALLATION

Plug and Receptacle

(models without electric starter)

T O B A T T E R Y

Battery Terminals

( ＋ ) TERMINAL

( − ) TERMINAL

RED

DC RECEPTACLE

COVER

BATTERY

− TO ACCESSORIES

To prepare the outboard motor for connection to a battery, pull the cover out of the DC receptacle, connect your battery charging wires to the receptacle. Attach the connected DC receptacle on the holder on the tiller arm.

The receptacle is provided with a cover, which should be attached when the plug is removed, in order to keep the receptacle clean and dry.

Battery

Minimum Requirements

12V-35AH

28

BLACK or GREEN

Connect the positive (+) battery cable to the positive (+) battery terminal, then connect the negative (-) battery cable to the negative (-) battery terminal.

The negative (-) battery cable should always be removed from the battery when connecting or disconnecting the positive (+) battery cable, so tools cannot cause a short circuit if they touch a grounded part while being used on the positive (+) battery terminal fitting.

02/03/25 20:55:10 31ZW8A00_030

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

INSTALLATION

29

02/03/25 20:55:24 31ZW8A00_031

BEFORE OPERATION

ARE YOU READY TO GET

UNDER WAY

？

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

Knowledge

Read and understand this manual.

Know what the controls do and how to operate them.

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

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

Safety

Always wear a PFD (Personal

Flotation Device) while on the boat.

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

IS YOUR OUTBOARD

MOTOR READY TO GO

？

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

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

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

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

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

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

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02/03/25 20:55:38 31ZW8A00_032

Safety Inspection

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

If you are using the portable fuel tank, make sure it is in good condition and properly secured in

the boat (p.

34 ).

Check that the fuel hose is undamaged and properly

connected (p.

34 ).

Wipe up any spills before starting the engine.

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

Check that all controls are operating properly.

Replace any damaged parts.

Check that all fasteners are in place and securely tightened.

Maintenance Inspection

Check the engine oil level (p.

56 ).

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

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

secured with the cotter pin (p.

70 ).

Check that the anodes are securely

attached to the gear case (p.

69 )

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

Make sure the tool kit and emergency starter rope are

onboard (p.

53 ). Replace any

missing items.

Check the fuel level in the fuel

tank (p.

63 ).

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

BEFORE OPERATION

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OPERATION

SAFE OPERATING

PRECAUTIONS

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

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

IMPORTANT SAFETY

INFORMATION chapter titled

on page 7

and the

BEFORE OPERATION.

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

BREAK-IN PROCEDURE

Break-in period: 10 hours

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

First 15 minutes:

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

Next 45 minutes:

Run the engine up to a maximum of

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

10% to 30% of maximum throttle opening.

Next 60 minutes:

Run the engine up to a maximum of

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

50% to 80% of maximum throttle opening.

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

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

Next 8 hours:

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

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02/03/25 20:56:07 31ZW8A00_034

TRANSOM ANGLE

ADJUSTMENT

(R type/XH type)

UNLOCKED

POSITION

ADJUSTING ROD

TO

CHANGE

LOCKED POSITION

(SH type/LH type)

ADJUSTING ROD

LOCKED POSITION

TO LOCK

PINCH

The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered.

Proper adjustment prevents the outboard motor from being trimmed

too low (p.

48 ).

To adjust, first tilt the outboard motor so it is not resting on the rod.

(R type/XH type)

Push the rod in and turn the end of the rod up, so the latch will fall into line with the rod.

(SH type/LH type)

Pinch the end of the rod.

Remove the rod and reinsert it in the desired position.

(R type/XH type)

Push the rod in and turn the end of the rod down, so the latch will fall to the locked position. Then release the rod.

OPERATION

(SH type/LH type)

Push the rod in and hook the end of the rod. Then release the rod.

Do not allow water to enter the idle exhaust port or the engine can be damaged.

IDLE EXHAUST PORT

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OPERATION

PORTABLE FUEL TANK

Secure the portable fuel tank in the boat, so it won’t move around and become damaged.

Before use, open the fuel tank vent by turning the vent knob at least 2 or

3 turns counterclockwise.

FUEL HOSE CONNECTIONS


Place the portable fuel tank in a wellventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.

To ensure that the outboard motor will be able to draw fuel from the tank, place the tank within 6 feet of the outboard motor and not more than 3 feet below the fuel connector on the outboard motor.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

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

Handle fuel only outdoors.

Wipe up spills immediately.

(FUEL TANK SIDE)


(OUTBOARD MOTOR SIDE)

Connect the fuel hose to the tank and the outboard motor, as shown. Be sure both connectors snap securely into place.

34

02/03/25 20:56:35 31ZW8A00_036

FUEL PRIMING

OUTLET END

(MOTOR)

PRIMING BULB

STARTING THE ENGINE

H Type (tiller handle)

SWITCH CLIP

ENGINE STOP

SWITCH

INLET END

(TANK)

Hold the priming bulb with the outlet end higher than the inlet end.

Squeeze the priming bulb several times, until it feels firm, indicating that fuel has reached the carburetor.

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

Do not squeeze the priming bulb when the engine is running because that could flood the carburetors.

LANYARD

1.

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

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

OPERATION

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

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

Always attach the lanyard to your

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

35

02/03/25 20:56:45 31ZW8A00_037

OPERATION

N (neutral) START POSITION

POINTER

THROTTLE GRIP

CHOKE KNOB

GEARSHIFT LEVER

2.

Check the position of the gearshift lever. It must be in the N (neutral) position for starting.

The engine will not start if the gearshift lever is in the F (forward) or R (reverse) position.

(manual choke type)

3.

To start a cold engine, pull the choke knob to the CLOSED position. To restart a warm engine, leave the choke knob in the OPEN position.

4.

Do not turn the throttle grip before starting and align the START position with the pointer for starting the engine.

36

02/03/25 20:56:59 31ZW8A00_038

STARTER GRIP


BUTTON

5.

Recoil starter

Pull the recoil starter grip slowly until you feel resistance, then pull briskly.

Return the starter grip gently.

OPERATION

Electric starter

(electric starter model)

Press the electric starter button and hold it there until the engine starts.

When the engine starts, release the button.

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

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

Pushing the electric starter button while the engine is running can damage the starter motor and f lywheel.

6.

If the choke knob was pulled to the CLOSED position to start the engine, gradually push it to the

OPEN position as the engine warms up.

Also, as the engine warms up, the throttle grip can be turned to the

SLOW position without stalling.

7.

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

During the warm-up period, check

the oil pressure indicator (p.

22 )

and cooling system indicator (p.

23 ).

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

TAKING CARE OF

UNEXPECTED PROBLEMS,

78 .

p.

37

02/03/25 20:57:12 31ZW8A00_039

OPERATION

R Type

(remote control)

For panel-mount or top-mount remote control information, refer to the instructions provided with the remote control equipment.

Side-Mount Type

SWITCH CLIP

LANYARD

1.

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

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

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

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

Always attach the lanyard to your

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

CONTROL

LEVER

N (neutral)

2.

Set the control lever in the N

(neutral) position.

The engine will not start if the F

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

38

02/03/25 20:57:24 31ZW8A00_040

OPERATION

FAST IDLE

FREE

ACCELERATION

RANGE

OFF

ON

START

FAST IDLE LEVER

3.

To start a cold engine, leave the fast idle lever in the OFF (fully lowered) position.

To restart a warm engine, raise the fast idle lever.

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

(neutral) position.

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

IGNITION SWITCH KEY

4.

Turn the ignition switch key to the

START position and hold it there until the engine starts.

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

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

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

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

39

02/03/25 20:57:37 31ZW8A00_041

OPERATION

5.

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

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

FAST IDLE LEVER

6.

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

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

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

2,000 rpm.

During the warm-up period, check the oil pressure indicator

(p.

22 ), overheating indicator (p.

22 ), and cooling system

indicator (p.

23 ).

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

CARE OF UNEXPECTED

PROBLEMS,

p.

78 .

EMERGENCY STARTING

If the battery is discharged, or the starter motor and the recoil starter are inoperative, you can start the engine manually using the emergency starter rope supplied with the tool kit.

UNLATCH

ENGINE COVER LATCH

1.

Unlatch and remove the engine cover.

40

02/03/25 20:57:50 31ZW8A00_042

NEUTRAL START CABLE

OPERATION

FLANGE BOLT

RECOIL STARTER

ASSEMBLY

FLYWHEEL (STARTER PULLEY)

KNOT

STARTER ROPE

RECOIL STARTER

ASSEMBLY

2.

Move the shift lever to the F

(forward) position. Loosen the neutral start cable lock nut and disconnect the neutral start cable.

Unscrew the three bolts and remove the recoil starter assembly.

3.

Set the controls the same as for

normal starting (see pages

40

35 −

). Use the choke and fast idle controls if needed.


ON position.

4.

Set the knotted end of the emergency starter rope in the notch in the flywheel. Wind the rope clockwise around the flywheel, as shown.

5.

Pull the emergency starter rope slowly until resistance is felt, then pull briskly.

Keep away from moving parts while pulling the rope.

If necessary, rewind the rope and pull again. If the engine does not start after several attempts, refer to

TAKING CARE OF

UNEXPECTED PROBLEMS,

78 .

p.

41

02/03/25 20:58:00 31ZW8A00_043

OPERATION

6.

If the choke and fast idle control(s) was used to start the engine, return the control(s) to the normal operating position as the engine warms up.

During the warm-up period, check

the oil pressure indicator (p.

22 ), overheating indicator (p.

22 ), and

cooling system indicator (p.

23 ).

7.

Leave the recoil starter assembly off, but install the engine cover (p.

20 ), and lock it in place by

latching the engine cover latch.

Exposed moving parts can cause injury.

Do not operate the outboard motor without the engine cover.

Use extreme care when installing the engine cover.

8.

If it was necessary to remove the emergency stop switch lanyard from your wrist to perform the emergency starting procedure, be sure the lanyard is attached to your wrist before operating the outboard motor.

9.

Have your closest authorized

Honda marine dealer check your electrical system and correct the problem, so you can use the electric starter.

The recoil starter assembly (p.

41 )

should be reinstalled after the electric starter is working again.

Install the recoil starter assembly with the engine stopped.

42

02/03/25 20:58:11 31ZW8A00_044

OPERATION

Normal Engine Stopping STOPPING THE ENGINE

Emergency Engine Stopping

LANYARD

PULL

SWITCH CLIP

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

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

SWITCH CLIP

LANYARD

THROTTLE GRIP

N (neutral)

SLOW

CONTROL

LEVER

1.

Move the throttle grip to the slowest speed and control gears to

N (neutral) position.

43

02/03/25 20:58:18 31ZW8A00_045

OPERATION

ENGINE STOP SWITCH

IGNITION SWITCH KEY

3.

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

2.


OFF position or press the engine stop switch until the engine stops.

44

02/03/25 20:58:29 31ZW8A00_046

OPERATION

GEARSHIFTING AND

THROTTLE OPERATION


SLOW

To shift gears, turn the throttle grip to the SLOW position, then move the gearshift lever to select F (forward),

N (neutral) or R (reverse) gears.

The engine can be started with the gearshift lever in the N (neutral) position only.

The throttle grip can be turned to the

FAST position only when the gearshift lever is in the F (forward) position.

THROTTLE GRIP

R (reverse)

N (neutral)

F (forward)

R E L E A S E

FIX

THROTTLE

FRICTION DIAL

THROTTLE GRIP

Use the throttle friction dial to help hold a constant throttle setting while cruising.

Turn the dial clockwise to increase throttle grip friction for holding a constant speed.

Turn the dial counterclockwise to decrease friction for easy grip rotation.

45

02/03/25 20:58:40 31ZW8A00_047

OPERATION

R Types


Side-Mount Type

CONTROL

LEVER

NEUTRAL

RELEASE LEVER

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

R (reverse) gears.

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

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

THROTTLE

FRICTION

ADJUSTER

TO INCREASE

FRICTION

TO DECREASE

FRICTION

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

46

02/03/25 20:58:52 31ZW8A00_048

STEERING


F R E E

L O C K

Steer by moving the tiller handle opposite the direction you want the boat to turn.

STEERING FRICTION LEVER

Use the steering friction lever to help hold a steady course while cruising.

Move the lever to the LOCK direction to increase steering friction for holding a steady course.

Move the lever to the FREE direction to decrease friction for easy turning.

OPERATION

R Type


Steer the boat in the same manner as an automobile.

47

02/03/25 20:59:04 31ZW8A00_049

OPERATION

CRUISING

Engine Speed

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

throttle friction control (p.

45 ) to

help you hold a steady speed.

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

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

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

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

Trim

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’’.

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

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

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

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

48

02/03/25 20:59:16 31ZW8A00_050

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

Motor Angle (Cruising)

O.K.

CORRECT

GIVES MAXIMUM PERFORMANCE

SHALLOW WATER

OPERATION

When operating in shallow water, tilt the outboard motor, using the tilt lever, so the propeller and gear case won’t hit the bottom.

OPERATION

To tilt the outboard motor, move the tilt lever to the TILT position, then raise the outboard motor to the 30° or

45° position by pulling on the engine cover grip.

45°

Do not use the tiller handle as a lever to raise the outboard motor.

Applying excessive f orce to the tiller handle can damage it.

While the outboard motor is tilted, proceed at a low speed, and do not operate the outboard motor in reverse.

The outboard motor will rise suddenly if operated in reverse.

Monitor water flow from the cooling

system indicator (p.

23 ) to be sure

the outboard motor is not tilted so high the water intake is out of the water.

30°

49

02/03/25 20:59:25 31ZW8A00_051

OPERATION

ENGINE COVER GRIP

MOORING, BEACHING,

LAUNCHING

An excessive tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.

TILT LEVER

T I L T

R U N

To return the outboard motor to the normal operating position, move the tilt lever to the RUN position, raise the outboard motor slightly to disengage the tilt mechanism, then slowly lower the outboard motor.

71° (when mooring)

To raise the outboard motor out of the water while the boat is moored, or for maximum clearance when beaching or launching, tilt the outboard motor to the 71° position.

Stop the engine before tilting the outboard motor. The 71° position is not an operating position.

Raise and lower the outboard motor

as described on p.

49 .

50

02/03/25 20:59:34 31ZW8A00_052

THE IMPORTANCE OF

MAINTENANCE

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

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

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

SERVICING YOUR OUTBOARD MOTOR

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

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

Remember that your authorized

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

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

Honda parts or their equivalents for repair and replacement.

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

EPA standards.

51

02/03/25 20:59:47 31ZW8A00_053


MAINTENANCE SAFETY

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

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

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

Safety Precautions

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

− Carbon monoxide poisoning from engine exhaust.

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

− Burns from hot parts.

Let the engine and exhaust system cool before touching.

− Injury from moving parts.

Do not run the engine unless instructed to do so.

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

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

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

52

02/03/25 20:59:54 31ZW8A00_054


TOOL KIT AND

EMERGENCY STARTER

ROPE

EMERGENCY STARTER ROPE

The following tools are supplied with the outboard motor for simple maintenance procedures and emergency repairs. An emergency starter rope is also supplied. Keep these items on the boat, so they will always be available if you need them.

OWNER’S MANUAL

8 × 10 mm WRENCH

PLIERS

10 × 12 mm WRENCH

OIL CHECK SCREWDRIVER

16.5 mm SOCKET

WRENCH

DRIVER

SPARE SWITCH CLIP TOOL BAG

53

02/03/25 21:00:05 31ZW8A00_055


MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

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

ITEM

Engine oil Check level

Change

Gear case oil

Engine oil filter

Starter rope

Carburetor linkage

Idling speed

Valve clearance

Spark plugs

Propeller and cotter pin

Lubrication

Fuel tank and tank filter

Change

Replace

Check

Check-adjust

Check-adjust

Check-adjust

Check-adjust

Replace

Check

Grease

Clean

Each use

○

○

After use

First month or

20 hrs.

○

○ (2)

○

○

(2)

(2)

○ (2)

○ (1)

Every

6 months or 100 hrs.

○

○

(2)

○

○

(2)

○ (2)

○

○ (1)

Every year or

200 hrs.

○

○ (2)

○

○

54

02/03/25 21:00:20 31ZW8A00_056


REGULAR SERVICE PERIOD (3)

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

ITEM

Fuel filter

Thermostat

Fuel line

Check

Replace

Check

Bolts and Nuts

Crankcase breather tube

Anode

Check

Replace

Check-tightness

Check

Check

Battery and cable connection

Cooling water passages

Check level-tightness

Clean

Emission related items.

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

Each use

○

○

○

After use

○ (4)

First month or

20 hrs.

Every 6 months or

100 hrs.

○

Every 2 years (if necessary) (2)

○ (2) ○ (2)

Every year or

200 hrs.

○

○ (2)

○ (2)

(2) 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.

55

02/03/25 21:00:36 31ZW8A00_057


ENGINE COVER REMOVAL

AND INSTALLATION

Engine Oil Level Check

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

1.

Unlatch and remove the engine cover.

2.

Remove the dipstick and wipe it clean.

OIL LEVEL DIPSTICK


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

To remove the engine cover, unlatch the engine cover latch, then lift the engine cover off the outboard motor.

To install the engine cover, place the cover on the outboard motor, then latch the engine cover latch securely.

UPPER

LIMIT

LOWER

LIMIT

3.

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

56

OIL FILLER CAP

4.

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

on p.

59 .

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

5.

Install the oil filler cap and tighten it securely.

6.

Install and lock the engine cover.

02/03/25 21:00:50 31ZW8A00_058


Engine Oil Change

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

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

1.

Unlatch and remove the engine

cover (p.

56 ).

ENGINE OIL DRAIN SCREW

2.

Remove the oil filler cap, and remove the engine oil drain screw.

3.

Allow the used oil to drain completely, then reinstall the engine oil drain screw, and tighten it securely.

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

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

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

4.

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

limit mark on the dipstick (p.

56 )

with the recommended oil.

Engine oil refill capacity:

Without oil filter change:

1.1 US qt (1.0

, 0.9 Imp qt)

With oil filter change:

1.4 US qt (1.3

, 1.1 Imp qt)

5.

Install the oil filler cap and tighten it securely.

6.


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02/03/25 21:01:04 31ZW8A00_059


Oil Filter Change

1.

Drain the engine oil, and reinstall the drain screw (see Engine Oil

Change on p.

57 ).

2.

Unscrew the six bolts and remove the R. engine under cover.

3.

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

4.

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

OIL FILTER TIGHTENING

TORQUE:

16 lbf·ft (22 N·m , 2.2 kgf·m)

6.

Fill the crankcase with the

specified amount (p.

57 ) of the

recommended oil.

7.

Start the engine and check for leaks.

USE A SUITABLE TOOL

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

Using the wrong f ilter, or a non-

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

5.

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

OIL FILTER

Running the engine without water can cause serious engine damage.

If you are changing the oil f ilter while the outboard motor is out of the water, use the water hose adapter (optional part) and a hose to supply water.

8.

Stop the engine, and check the oil

level as described on page 56

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

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02/03/25 21:01:12 31ZW8A00_060

Engine Oil Recommendations

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

4-stroke automotive detergent oil.

SAE Viscosity Grades


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

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

AMBIENT TEMPERATURE

SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range.

59

02/03/25 21:01:20 31ZW8A00_061


Lubrication Points

Wipe the outside of the engine with a cloth dipped in oil.

Apply marine anticorrosion grease to the following parts: lubrication, then every 20 hours or a month after the date of purchase for initial 100 hours or 6 months.

TILLER HANDLE

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

CLAMP SCREWS

THROTTLE REEL TILT STOPPER

SWIVEL CASE

ADJUSTING ROD

PROPELLER SHAFT

Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover except the belts.

60

02/03/25 21:01:31 31ZW8A00_062


Spark Plug Service

RECOMMENDED SPARK PLUGS:

CR5EH-9 (NGK)

U16FER9 (DENSO)

SPARK PLUG

WRENCH

SPARK PLUG CAP

0.031

− 0.035 in

(0.80

− 0.90 mm)

Incorrect spark plugs can cause engine damage.

1.

Unlatch and remove the engine

cover (p.

56 ).

2.

Disconnect the spark plug caps from the spark plugs.

3.

Remove the spark plugs with a spark plug wrench and screwdriver supplied in the tool kit.

4.

Inspect the spark plugs. Replace them if the electrodes are worn, or if the insulators are cracked or chipped. Clean the spark plugs with a wire brush if you are going to reuse them.

5.

Measure the spark plug electrode gap with a suitable gauge. The gap should be 0.031

− 0.035 inches

(0.80

− 0.90 mm).

61

02/03/25 21:01:40 31ZW8A00_063


7.

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

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

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

6.

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

Loose spark plugs can overheat and damage the engine.

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

8.

Attach the spark plug caps.

9.


62

02/03/25 21:01:53 31ZW8A00_064


REFUELING

Portable Fuel Tank

(optional equipment)

FUEL TANK CAPACITY:

3.2 US gal (12 , 2.6 Imp gal)

Check the fuel gauge and refill the tank when necessary.

Remove the fuel tank from the boat for refueling.

VENT KNOB

CLOSE

OPEN

FUEL CAP

To refuel, turn the vent knob counterclockwise to the OPEN position, and unscrew the fuel tank cap.

SAFE FILL LEVEL

FUEL GAUGE

Refuel in a well-ventilated area. Fill the tank to the SAFE FILL LEVEL line.

After refueling, install the cap and tighten it securely. Turn the vent knob clockwise to the CLOSED position, and return the fuel tank to the boat.

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02/03/25 21:02:05 31ZW8A00_065







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

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


FUEL RECOMMENDATIONS

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

Your outboard motor is certified to operate on unleaded gasoline.

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

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

Avoid getting dirt or water in the fuel tank.

Occasionally you may hear a light

‘‘spark knock’’ or ‘‘pinging’’

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

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02/03/25 21:02:17 31ZW8A00_066

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

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

Running the engine with persistent spark knock or pinging is misuse, and the Distributor’s Limited

Warranty does not cover parts damaged by misuse.


Fuel Pump Filter Inspection and Replacement

The fuel pump filter is located under the engine cover, on the right side of the engine.

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






65

02/03/25 21:02:25 31ZW8A00_067


UNLATCH


1.

Unlatch and remove the engine cover for access to the fuel pump filter.

FUEL FILTER

2.

Inspect the filter for water and/or sediment accumulation.

If the filter is OK, reinstall it. If water and/or sediment are present, replace the filter as described in the following steps. Always replace the filter at the scheduled

replacement interval (p.

55 ).

3.

Disconnect the fuel hose from the outboard motor, and place clamps on the fuel hoses on each side of the filter to prevent fuel leakage when the fuel hoses are disconnected.

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02/03/25 21:02:34 31ZW8A00_068

FUEL FILTER FUEL HOSE

4.

Remove the fuel tubes from the used filter, and discard the filter.

To ease tube removal, release the tube clips by squeezing the clip ends together with pliers while pulling off the tubes.


5.

Install the new filter on the fuel hoses, with the fuel flow arrow pointing toward the fuel pump as shown. Fuel flow will be impeded if the filter is installed backward.

6.

Remove the fuel tube clamps, and connect the fuel hose to the outboard motor. Check for leaks.

7.


ARROW

(Fuel Flow Direction)

67

02/03/25 21:02:43 31ZW8A00_069


Portable Fuel Tank and Filter

Cleaning

Fuel Tank

Empty the portable fuel tank into an approved gasoline container. Use a funnel to avoid spilling fuel. Rinse the fuel tank with nonflammable solvent to remove any accumulated sediment.

Fuel Tank Filter

TANK FILTER JOINT

(Fuel Connector)

FILTER

1.

Unscrew the fuel hose connector by turning it counterclockwise, then remove the fuel hose connector and fuel filter from the tank.

2.

Clean the filter in nonflammable solvent. Inspect the fuel tank filter and the connector O-ring. Replace them if damaged.

3.

Reinstall the filter and hose connector in the fuel tank. Tighten the hose connector securely.

68

02/03/25 21:02:53 31ZW8A00_070


Recoil Starter Rope Inspection

RECOIL STARTER ROPE

Anode Replacement

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

Inspect the recoil starter rope, and replace it if it becomes frayed.

Always keep the emergency starter rope on the boat in case the recoil starter rope fails.

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

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

69

02/03/25 21:03:04 31ZW8A00_071


Removal Propeller Replacement

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

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

COTTER PIN

Installation

TOWARD

GEAR CASE

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

PROPELLER

PLAIN

WASHER

CASTLE

NUT

COTTER PIN

THRUST WASHER

1.

Install the propeller in the reverse order of removal.

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

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

70

02/03/25 21:03:20 31ZW8A00_072

STORAGE

STORAGE PREPARATION

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

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

Cleaning and Flushing

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

Cleaning

Wash the outside of the outboard motor with clean, fresh water to remove mud, salt, seaweed, etc.

Disengage the emergency engine stop switch clip from the engine stop switch, and pull the recoil starter rope several times to expel any water remaining in the water pump.

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

Corrosion Inhibitor, or equivalent.

Lubricate controls with a silicone spray lubricant.

Flushing With the Honda

Garden Hose Adapter

1.

Unlatch the engine cover latch and

remove the engine cover (p.

56 ),

and install the garden hose adapter.

2.

Attach a garden hose from a fresh water faucet to the garden hose adapter.

3.

Turn on the fresh water supply, and verify that there is good water pressure at the outboard motor.

4.

Flush the engine with fresh water for at least 10 minutes.

GARDEN HOSE

ADAPTER

After flushing, remove the garden hose adapter, reinstall the engine cover.

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02/03/25 21:03:28 31ZW8A00_073

STORAGE

Flushing Without the Honda

Garden Hose Adapter

It is necessary to run the engine during the flushing procedure. For safety, remove the propeller from the

outboard motor (p.

70 ).

Running the engine without good water circulation can cause overheating and water pump damage.

Damage caused by running the outboard motor without sufficient cooling water is not covered by the

Distributor’s Limited Warranty.

2.

Start the engine and run in (N) neutral at low speed for at least 10 minutes.

3.

After flushing, stop the engine, remove the water container, and

reinstall the propeller (p.

70 ).

ANTIVENTILATION PLATE

1.

Place a container under the outboard motor, and fill it with clean, fresh water. The water level must be at least 2 inches above the antiventilation plate.

72

02/03/25 21:03:41 31ZW8A00_074

STORAGE

Fuel

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

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

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

The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation.

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

1.

Disconnect the fuel hose from the outboard motor.

DRAIN SCREW

2.

With the outboard motor in a vertical position, place an approved gasoline container below the fuel drain outlet, and use a funnel to avoid spilling fuel.

Loosen the drain screw to drain fuel from the carburetor.






3.

After the fuel has drained from the carburetor, tighten the drain screw securely.

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02/03/25 21:03:45 31ZW8A00_075

STORAGE

4.

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

74

02/03/25 21:03:58 31ZW8A00_076

Engine Oil

1.

Change the engine oil and the oil

filter (p.

57 − 58 ).

2.

Remove the spark plugs (p.

61 ),

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

3.

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

4.

Pull the starter rope several times to distribute the oil in the cylinders.

5.

Reinstall the spark plugs (p.

62 ).

STORAGE PRECAUTIONS

Select a well-ventilated storage area.

If possible, avoid storage areas with high humidity.

CARRYING HANDLE

STORAGE

To carry the outboard motor, hold it by the carrying handle, or hold by the carrying handle and the lug beneath the engine cover latch, as shown.

Lif ting the outboard motor by the engine cover, or using the installed outboard motor as a handle or lever to move the boat, can damage the outboard motor.

If your portable fuel tank contains gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark-producing electric motor, or where power tools are operated.

LUG

75

02/03/25 21:04:07 31ZW8A00_077

STORAGE

Store the outboard motor either vertically or horizontally with the tiller handle side up.

PROTECTOR CASE PROTECTOR

If storing horizontally, be sure to fold the tiller handle, and the outboard motor rests on its case protectors. Be sure all water has drained from the outboard motor before placing it on its side, so no residual water can enter the engine exhaust port.

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

REMOVAL FROM STORAGE

Check your outboard motor as described in the BEFORE

OPERATION chapter of this manual.

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

This is normal.

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

76

02/03/25 21:04:18 31ZW8A00_078

WITH OUTBOARD MOTOR

INSTALLED ON BOAT

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

friction lever securely (p.

47 ).

If there is insufficient road clearance in the normal running position, then tilt the outboard motor and use a motor support bar, or remove the outboard motor from the boat. Refer to the manufacturer’s instructions for using a motor support bar.

WITH OUTBOARD MOTOR

REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position

shown on p.

76 .

CARRYING HANDLE

TRANSPORTING

To carry, hold the outboard motor by the carrying handle, or hold by the carrying handle and the lug beneath engine cover lock lever, as shown.

Lif ting the outboard motor by the engine cover, or using the installed outboard motor as a handle or lever to move the boat, can damage the outboard motor.

MOTOR SUPPORT BAR

(commercially available)

LUG

77

02/03/25 21:04:31 31ZW8A00_079

TAKING CARE OF UNEXPECTED PROBLEMS

ELECTRIC STARTER WILL

NOT OPERATE

1.

Check battery.

Possible Cause

2.

Check fuses.

3.

Use emergency starting procedure (p.

40 ), then take outboard motor to an authorized

Honda Marine dealer, or refer to the shop manual.

Battery connections loose or corroded.

Battery discharged.

Fuse(s) burnt out.

Starter malfunction, switch malfunction, or electrical problem in the starting circuit.

Correction

Clean and tighten battery connections.

Recharge battery.

Replace fuse(s) (p.

83 ).

Replace or repair faulty components as necessary.

78

02/03/25 21:04:44 31ZW8A00_080

ENGINE WILL NOT START

1.

Check emergency stop switch clip.

2.

Check control positions.


Possible Cause

Clip not inserted in stop switch.

Correction

Insert clip in stop switch.

Gearshift lever or control lever not in neutral position.

Choke OPEN (tiller-handle and manual choke type).

Throttle grip not in START position (tiller-handle type).

Fast idle lever raised (side-mount type).

Shift to neutral (p.

15 ).

Pull choke knob to CLOSED position, unless engine is warm (p.

14 ).

Turn throttle grip to START

position (p.

36 ).

Leave fast idle lever OFF, unless

engine is warm (p.

39 ).

79

02/03/25 21:05:02 31ZW8A00_081


80

ENGINE WILL NOT START

(continued)

3.

Check fuel.

5.

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

Possible Cause

4.

Remove and inspect spark plugs.

Out of fuel.

Fuel vent closed (portable fuel tank).

Fuel hose not primed.

Fuel pump filter or fuel tank filter clogged.

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

Spark plugs faulty, fouled or improperly gapped.

Spark plugs wet with fuel (flooded engine).

Carburetor malfunction, fuel pump failure, ignition malfunction, stuck valves, etc.

Correction

Refuel (p.

65 ).

Open fuel tank vent (p.

24 ).

Squeeze priming bulb (p.

33 ).

Replace fuel filters (p.

65 ).

Drain fuel tank and carburetors (p.

73 ). Refill with fresh gasoline (p.

63 ).

Clean, gap or replace spark plugs

(p.

61 ).

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


02/03/25 21:05:19 31ZW8A00_082


HARD STARTING OR STALLS

AFTER STARTING

1.

Check control positions.

Possible Cause

Choke OPEN (tiller-handle type).

2.

Check fuel.

Throttle grip not in START position (tiller-handle type).

Fast idle lever raised (side-mount type).

Fuel vent closed (portable fuel tank).

Fuel hose not primed.

Fuel pump filter or fuel tank clogged.

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

Correction

Pull choke knob to CLOSED position, unless engine is warm (p.

14 ).

Turn throttle grip to START (p.

36 ).

Leave fast idle lever OFF, unless

engine is warm (p.

39 ).

Open fuel tank vent (p.

24 ).

Squeeze priming bulb (p.

33 ).

Replace fuel filters (p.

65 ).

Drain fuel tank and carburetors (p.

73 ). Refill with fresh gasoline (p.

63 ).

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02/03/25 21:05:34 31ZW8A00_083


HARD STARTING OR STALLS

AFTER STARTING

(continued)

3.

Remove and inspect spark plugs.

Possible Cause

4.


Spark plugs faulty, fouled or improperly gapped.

Carburetor malfunction, fuel pump failure, ignition malfunction, etc.

Correction

Clean, gap or replace spark plugs

(p.

61 ).


ENGINE OVERHEATS

1.

Check water intake screens.

2.


Possible Cause

Water intake screens clogged.

Faulty thermostat or water pump.

Correction

Clean water intake screens.


82

02/03/25 21:05:48 31ZW8A00_084

BATTERY WILL NOT

CHARGE AND ELECTRIC

STARTER WILL NOT

OPERATE

The battery-charging circuit and the electric starter relay circuit are protected by the 20-ampere fuse. If the fuse burns out, the engine will not charge the battery, and the electric starter will not operate. The engine can be started using the recoil starter or the emergency starter rope.

The ignition switch is protected by the 20-ampere fuse. If the fuse burns out, the engine will not start or run.

Fuse Replacement

1.

With the engine stopped, remove the engine cover.

2.

Remove the fuse case lid.


3.

Remove and inspect the fuses. If a fuse is burnt out, install a replacement fuse of the specified rating. The outboard motor is supplied with spare fuses in the fuse holders.

DESIGNATED FUSE: 20A

SPARE 20A FUSE

20A FUSE FUSE CASE LID

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

BLOWN FUSE

4.

Reinstall the fuse case lid and the engine cover.

Before further operation, try to determine and correct the electrical problem that caused the fuse to burn out. An uncorrected electrical problem may cause the fuse to burn out again.

83

02/03/25 21:05:58 31ZW8A00_085


OIL PRESSURE INDICATOR

LIGHT GOES OFF AND

ENGINE SPEED IS LIMITED

OIL PRESSURE

(GREEN)

(tiller handle type)

(GREEN)

(remote control type)

If oil pressure becomes low, the green indicator light will go off, and the engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease gradually.

Remote-control types are equipped with a buzzer that sounds when the green indicator light goes off.

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

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

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

(p.

56 ), and add oil if needed.

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

OK, the green indicator light should come on within 30 seconds, and the engine will respond normally to throttle grip or control lever operation.

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

84

02/03/25 21:06:10 31ZW8A00_086


OVERHEATING INDICATOR

LIGHT COMES ON AND

ENGINE SPEED IS LIMITED

(RED)

If the engine overheats, the red indicator light will come on, and the engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease gradually.

Remote-control types are equipped with a buzzer that sounds when the red indicator light comes on.

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

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

COOLING SYSTEM INDICATOR

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

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

30 seconds. If the cooling system is

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

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

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

85

02/03/25 21:06:19 31ZW8A00_087


SUBMERGED MOTOR

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

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

1.

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

2.

Drain the carburetors as described

on p.

73 .

3.

Change the engine oil and oil filter

as described on p.

57 − 58 . If

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

STARTER GRIP

4.

Remove the spark plugs (p.

61 ),

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

Pull the recoil starter grip, rotate the flywheel a few revolutions to completely expel any water from the cylinders.

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

86

02/03/25 21:06:29 31ZW8A00_088

When cranking the engine with an open ignition circuit (spark plugs removed f rom the ignition circuit), remove the clip f rom the emergency or engine stop switch to prevent possible damage to the ignition system.


5.

Pour a teaspoon of engine oil into each spark plug hole, then pull the recoil starter grip several times to lubricate the inside of the cylinders.

6.

Reinstall the spark plugs, and put the emergency stop switch clip into the switch.

7.

Attempt to start the engine.

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

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

8.

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

Honda Marine dealer for inspection and service.

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02/03/25 21:06:38 31ZW8A00_089

TECHNICAL AND CONSUMER INFORMATION

TECHNICAL INFORMATION

Serial Number Locations

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

97 ).

PRODUCT IDENTIFICATION

NUMBER

SWIVEL CASE

ENGINE SERIAL NUMBER

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

Product identification number:

The engine serial number is stamped on the right front of the engine.

Engine serial number:

88

02/03/25 21:06:48 31ZW8A00_090


Carburetor Modification for

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 plugs and cause hard starting.

High altitude performance can be improved by specific modifications to the carburetors. If you always operate your outboard motor at altitudes above 5,000 feet (1,500 meters), have an authorized Honda marine dealer perform this carburetor modification.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each 1,000-foot (300meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When the carburetors have been modif ied f or high altitude operation, the air-f uel mixture will be too lean f or low altitude use. Operation at altitudes below 5,000 f eet (1,500 meters) with modif ied carburetors may cause the engine to overheat and result in serious engine damage.

For use at low altitudes, have an authorized Honda Marine dealer return the carburetors to original f actory specif ications.

Battery

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

Minimum Requirements

12V-35AH

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Oxygenated Fuels

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

Canada use oxygenated fuels to help reduce emissions.

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

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

The following are the EPA-approved percentages of oxygenates:

ETHANOL: ethyl or grain alcohol;

10% by volume.

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

MTBE: Methyl Tertiary Butyl Ether;

15% by volume.

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

METHANOL: methyl or wood alcohol; 5% by volume.

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

90

damage metal, rubber, and plastic parts of your fuel system.

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

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

02/03/25 21:07:10 31ZW8A00_092


Emission Control System

Information

Source of Emissions

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

Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

The U.S. Clean Air Act

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

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

Honda engine within the emission standards.

Tampering and Altering

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

Among those acts that constitute tampering are:

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

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

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Problems That May Af f ect

Emissions

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

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

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

EPA emission regulations. We recommend the use of genuine

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

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

Maintenance

Follow the maintenance schedule on

p.

54 . Remember that this schedule

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

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Star Label

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

Air Resources Board.


The Star Label means Cleaner Marine Engine

This engine has been certified as a:

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water for healthier lifestyle and environment.

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

Longer Emission Warranty protects consumer for worry free operation.

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One Star

Low Emission

Two Stars

Very Low Emission

Three Stars

Ultra Low Emission

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

2001 exhaust emission standards.

Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

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


Engines meeting these standards have 20% lower emissions than One

Star-Low-Emission engines.

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


Engines meeting these standards have 65% lower emissions than One

Star-Low-Emission engines.

Cleaner Watercraft - Get the Facts

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

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Specifications

MODEL

Description Code

Type

Overall length

Overall width

Overall height

Transom height

Weight

S

L

X

S

L

X

S

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

Lubrication system

Specified oil

L

X

BF8D/BFP8D

BAAJ

H HS

24.0 in (610 mm)

92.6 lbs

(42.0 kg)

13.6 in (345 mm)

43.5 in (1,105 mm)

48.6 in (1,235 mm)

54.1 in (1,375 mm)

17.0 in (433 mm)

22.2 in (563 mm)

27.7 in (703 mm)

102.5 lbs

(46.5 kg)

R

23.6 in (600 mm)

103.6 lbs

(47.0 kg)

98.1 lbs

(44.5 kg)

108.0 lbs

(49.0 kg)

109.1 lbs

(49.5 kg)

106.9 lbs

(48.5 kg)

116.8 lbs

(53.0 kg)

117.9 lbs

(53.5 kg)

6.0 kW (8.0 HP)

4,500 − 5,500 rpm

4 stroke OHC in-line 2 cylinder, water-cooled

13.5 cu-in (222 cm )

0.031

− 0.035 in (0.80

− 0.90 mm)

Recoil starter Electric starter

C.D.I

Trochoid pump pressure lubrication

Engine: API standard (SG, SH, SJ)

SAE 10W-30

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

SAE 90 outboard motor gear oil

Oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Tank capacity

Gear change

Steering angle

Transom angle

Tilt angle

Remote control steering system

Tune Up

Spark plug gap

Idle speed

Valve clearance

(cold)

Other specifications

Engine: 1.4 US qt (1.3

, 1.1 Imp qt)

Gear case: 0.301 US qt (0.285

, 0.251 Imp qt)

12V −

ULTRA · LOW EMISSION

6A 12V − 12A 12V − 12A

Water cooling with thermostat

Water exhaust

CR5EH-9 (NGK) , U16FER9 (DENSO)

Diaphragm type fuel pump

Automotive unleaded gasoline

(86 pump octane or higher)

3.2 US gal (12 , 2.6 Imp gal)

Forward-Neutral-Reverse

(dog type)

45° right and left

5 stages (4°-8°-12°-16°-20°)

3 stages adjustment (30°, 45° and 71°)

Motormounted

0.031

− 0.035 in

(0.80

− 0.90 mm)

900 ± 50 rpm

See page 62

See shop manual

Intake:

Exhaust:

0.17

± 0.02 mm

0.23

± 0.02 mm

See shop manual

No other adjustment is needed

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

95

02/03/25 21:09:27 31ZW8A00_097


Specifications

MODEL

Description Code

Type

Overall length

Overall width

Overall height

Transom height

Weight

S

L

X

S

L

X

S

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Starter system

Ignition system

Lubrication system

Specified oil

L

X

BF9.9D/BFP9.9D

BABJ

H HS

24.0 in (610 mm)

13.6 in (345 mm)

43.5 in (1,105 mm)

48.6 in (1,235 mm)

54.1 in (1,375 mm)

17.0 in (433 mm)

22.2 in (563 mm)

R

23.6 in (600 mm)

92.6 lbs

(42.0 kg)

98.1 lbs

(44.5 kg)

27.7 in (703 mm)

102.5 lbs

(46.5 kg)

108.0 lbs

(49.0 kg)

103.6 lbs

(47.0 kg)

109.1 lbs

(49.5 kg)

106.9 lbs

(48.5 kg)

116.8 lbs

(53.0 kg)

7.4 kW (9.9 HP)

117.9 lbs

(53.5 kg)

5,000 − 6,000 rpm

4 stroke OHC in-line 2 cylinder, water-cooled

13.5 cu-in (222 cm )

0.031

− 0.035 in (0.80

− 0.90 mm)

Recoil starter Electric starter

C.D.I

Trochoid pump pressure lubrication

Engine: API standard (SG, SH, SJ)

SAE 10W-30

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

SAE 90 outboard motor gear oil

Oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Tank capacity

Gear change

Steering angle

Transom angle

Tilt angle

Remote control steering system

Tune Up

Spark plug gap

Idle speed

Valve clearance

(cold)

Other specifications

Engine: 1.4 US qt (1.3

, 1.1 Imp qt)

Gear case: 0.301 US qt (0.285

, 0.251 Imp qt)

12V −

ULTRA · LOW EMISSION

6A 12V − 12A 12V − 12A

Water cooling with thermostat

Water exhaust

CR5EH-9 (NGK) , U16FER9 (DENSO)

Diaphragm type fuel pump

Automotive unleaded gasoline

(86 pump octane or higher)

3.2 US gal (12 , 2.6 Imp gal)

Forward-Neutral-Reverse

(dog type)

45° right and left

5 stages (4°-8°-12°-16°-20°)

3 stages adjustment (30°, 45° and 71°)

Motormounted

0.031

− 0.035 in

(0.80

− 0.90 mm)

900 ± 50 rpm

See page 62

See shop manual

Intake:

Exhaust:

0.17

± 0.02 mm

0.23

± 0.02 mm

See shop manual

No other adjustment is needed

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

96

02/03/25 21:09:44 31ZW8A00_098


CONSUMER INFORMATION

Honda Publications

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

Shop Manual

This manual covers complete maintenance and overhaul procedures.

It is intended to be used by a skilled technician.

Parts Catalog

This manual provides complete, illustrated parts lists.

Warranty Service Information

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

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

Marine Customer Relations Office.

You can write:

American Honda Motor Co., Inc.

Marine Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400

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

Model and serial numbers (p.

88 )

Name of the dealer who sold the outboard motor to you

Name and address of the dealer who services your outboard motor

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

97

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INDEX

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

. 23

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

. 69

ARE YOU READY TO GET UNDER WAY ？

ATTACHMENT

.........

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

. 30

. 26

Automatic Choke (equipped type only) ........................

. 23

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

. 89

BATTERY CONNECTIONS .......................................

. 27

BATTERY WILL NOT CHARGE AND

ELECTRIC STARTER WILL NOT

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

. 83

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

. 30

BOAT TRANSOM REQUIREMENTS .......................

. 25

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

. 32

Carburetor Modification for High Altitude

Operation ...................................................................

. 89

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

. 71

Choke Knob (H type manual choke) ............................

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

. 14

. 11

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

. 97

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

. 14

CONTROLS AND FEATURE IDENTIFICATION

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

. 10

CONTROLS AND FEATURES

CRUISING

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

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

. 23

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

. 10

. 48

Electric Starter Button (models equipped with electric starter) ...........................................................

. 16

EMERGENCY STARTING .........................................

. 40

Emission Control System Information

Engine

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

. 91

Cover

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

. 20

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

. 56

Oil

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

. 57

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

. 56

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

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

. 59

. 14

Fuel

Cap Vent Knob ..........................................................

. 24

HOSE CONNECTIONS ...........................................

. 34

Gauge .........................................................................

. 21

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

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

. 35

. 24

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

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

. 64

. 65

101

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INDEX

H Type (tiller handle) ................................................

. 45

R Type (remote control) ............................................

. 46

Gearshift Lever ..............................................................

. 15

Gearshift/Trottle Control Lever ....................................

. 18

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

. 16

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

. 7

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

. 22

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

. 25

INSTALLATION POSITION ......................................

. 26

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

. 21

IS YOUR OUTBOARD MOTOR

READY TO GO ？ ....................................................

. 30

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

. 60

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

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

. 52

. 54

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

. 50

Oil filter Change ............................................................

. 58

Oil Pressure Indicator (R type) (H type) .......................

OIL PRESSURE INDICATOR LIGHT GOES

. 22

OFF AND ENGINE SPEED IS LIMITED

OPERATION

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

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

. 84

. 32

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

. 23

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

. 7

Overheating Indicator (R type) .....................................

OVERHEATING INDICATOR LIGHT COMES

. 22

ON AND ENGINE SPEED IS LIMITED

(remote control type) .............................................

. 85

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

. 23

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

. 90

102

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INDEX

PORTABLE FUEL TANK .....................................

. 24, 34

Portable Fuel Tank and Filter Cleaning ........................

. 68

POWER REQUIREMENTS .........................................

. 25

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

. 70

Recoil Starter

Grip ............................................................................

. 16

Rope Inspection .........................................................

. 69

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

. 65

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

. 76

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

. 32

SAFETY LABEL LOCATIONS ....................................

. 9

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

. 88

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

. 51

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

. 49

Spark Plug Service

Specifications

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

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

. 61

. 95

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

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

. 93

. 35


. 35


. 38

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

. 47


. 47


. 47

Steering Friction Lever ..................................................

. 21

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

. 43

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

. 43

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

. 43

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

. 71

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

. 75

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

. 71

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

. 73

Engine oil ..................................................................

. 75

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

. 86

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

. 17

103

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INDEX

TAKING CARE OF UNEXPECTED PROBLEMS ....

. 78

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

. 88

THE IMPORTANCE OF MAINTENANCE

Throttle Friction Dial

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

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

. 51

. 15

Throttle Grip ..................................................................

. 15

Tilt Lever .......................................................................

. 21

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

. 20

TRANSOM ANGLE ADJUSTMENT ....................

. 27,33

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

. 77

WITH OUTBOARD MOTOR INSTALLED

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

. 77

WITH OUTBOARD MOTOR REMOVED

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

. 77

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

. 98

104

Honda Marine BFP9.96D Owner's Manual 107 Pages

Honda Marine BFP9.96D Owner's Manual

INTRODUCTION

INTRODUCTION

A FEW WORDS ABOUT

SAFETY

2

CONTENTS

CONTENTS

CONTENTS

CONTENTS

IMPORTANT SAFETY

INFORMATION

OUTBOARD MOTOR SAFETY

Operator Responsibility

7

OUTBOARD MOTOR SAFETY

Refuel With Care

Carbon Monoxide Hazard

8

SAFETY LABEL LOCATIONS

OUTBOARD MOTOR SAFETY

9

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

10

CONTROLS AND FEATURES

COMPONENT AND CONTROL LOCATIONS

H Type (tiller handle)

11

CONTROLS AND FEATURES

R Type (remote control)

12

CONTROLS AND FEATURES

CONTROLS AND FEATURES

CONTROLS

H Type (tiller handle)

Engine Stop Switch and Switch

Clip

Choke Knob (H type manual choke)

14

Throttle Grip

Throttle Friction Dial

CONTROLS AND FEATURES

Gearshif t Lever

CONTROLS AND FEATURES

Recoil Starter Grip

Electric Starter Button (models equipped with electric starter)

R Type (remote control)

Ignition Switch (side-mount type)

16

CONTROLS AND FEATURES

Switch Clip and Emergency Stop

Switch (side-mount type)

CONTROLS AND FEATURES

Fast Idle Lever

(side-mount type)

Gearshif t/Throttle Control

Lever (side-mount type)

CONTROLS AND FEATURES

CONTROLS AND FEATURES

Common Controls

Engine Cover Latch

Transom Angle Adjusting Rod

20

Steering Friction Lever Tilt Lever

CONTROLS AND FEATURES

INSTRUMENTS

Fuel Gauge

21

CONTROLS AND FEATURES

INDICATORS

Oil Pressure Indicator

(R type)

(H type)

Overheating Indicator

(R type)

22

Cooling System Indicator

CONTROLS AND FEATURES