Honda BF75D Owner's Manual 161 Pages

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Honda BF75D Owner's Manual | Manualzz

Thank you for purchasing a Honda

Outboard Motor.

This manual covers operation and maintenance of the Honda BF75D/

90D Outboard Motor.

All information in this publication is based on the latest product information available at the time of approval for printing.

Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

This manual should be considered a permanent part of the Outboard

Motor and should remain with it if it is resold.

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

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

Outboard Motor, consult an authorized Honda Outboard Motor dealer.

Indicates serious injury or death WILL result if instructions are not followed.

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

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

Manual before operating the

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

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

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

Gives helpful information.

Honda Motor Co., Ltd. 2006, All

Rights Reserved

1

Model

Type

Shaft Length

(Transom Height)

537 mm

(21.1 in)

664 mm

(26.1 in)

Tiller Handle

Remote Control

Power Trim/Tilt

Trim meter

Tachometer

LHTD LHTW

BF75D

LRTD

LRTW

LRTL

LRTU

XRTW XRTL

XRTU

LHTD LHTW

BF90D

LRTD

LRTW

LRTL

LRTU

XRTD

XRTL

XRTW

XRTU

* *

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

BF75D/90D is provided with the following types according to the shaft length, control system, and tilt system.

* : Optional Equipment

TYPE CODE

L R T D

Example

Destination

U, W: Europe, D: General Export, L: Australian

Tilt system

T: Power Trim/Tilt (with hydraulic assisted function)

Control System

H: Tiller Handle Control,

R: Remote Control

Shaft Length

L: 537 mm (21.1 in) (Long Shaft),

X: 664 mm (26.1 in) (Extra Long Shaft)

2

This Owner’s Manual is using the following type names when it describes the operations special to a type.

Tiller handle type:

Remote control type:

H type

R type

The remote control type is classified into the following three categories according to the control box position.

R1 type Side-mount type:

Panel-mount type:

Top-mount type:

R2 type

R3 type

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

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

FRAME SERIAL NUMBER

RIGHT STERN BRACKET

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

The frame serial number is stamped on the right stern bracket.

ENGINE SERIAL NUMBER

The engine serial number is stamped on the upper right side of the motor.

Frame serial number: Engine serial number:

3

CONTENTS

4

1. SAFETY .......................................................................................

. 7

SAFETY INFORMATION .....................................................

. 7

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

. 10

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

. 13

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

. 21

H Type

Engine Switch ....................................................................

. 21

Shift Lever .........................................................................

. 21

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

. 22

Throttle Friction Adjuster ..................................................

. 22

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

. 23

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

. 23

Steering Friction Adjusting Knob

R Type

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

. 24

Remote Control Lever .......................................................

. 25

R1 Type ..........................................................................

. 25

R2 Type ..........................................................................

. 26

R3 Type ..........................................................................

. 27

Neutral Release Lever ........................................................

. 28

Engine Switch (Ignition Switch) .......................................

. 28

Fast Idle Lever/Fast Idle Button ........................................

. 29

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

. 30

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

. 30

Spare Emergency Stop Switch Clip

Common

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

. 31

Oil Pressure Indicator/Buzzer ............................................

. 32

Overheat Indicator/Buzzer .................................................

. 32

ACG Indicator/Buzzer .......................................................

. 33

PGM-FI Indicator/Buzzer ..................................................

. 34

Water Separator Buzzer .....................................................

. 34

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

. 35

Trim Meter (equipped type or optional equipment) ..........

. 36

Power Tilt Switch (motor pan) ..........................................

. 36

Manual Relief Valve ..........................................................

. 37

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

. 37

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

. 38

Anode .................................................................................

. 38

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

. 39

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

. 39

Engine Cover Fixing Lever ...............................................

. 40

Tachometer (equipped type or optional equipment) .........

. 40

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

. 40

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

. 41

Fuel Filler Cap (equipped type) .........................................

. 41

Fuel Line Connector And Joint (equipped type) ...............

. 42

5. INSTALLATION .......................................................................

. 43

Transom Height .....................................................................

. 43

Location ..................................................................................

. 44

Installation Height ..................................................................

. 44

Outboard Motor Installation ..................................................

. 45

Motor Angle Inspection (Cruising) .......................................

. 46

Battery Connections ...............................................................

. 47

Remote Control Installation (equipped type or optional equipment) .....................................................................

. 49

Remote Control Box Location ..........................................

. 50

Remote Control Cable Length ...........................................

. 50

Propeller Selection .................................................................

. 51

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

. 52

Engine Cover Removal/Installation

Engine Oil

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

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

. 52

. 53

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

. 55

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

. 56

Propeller and Cotter Pin Inspection .......................................

. 57

Tiller Handle Height/Angle Adjustment (H Type) ...............

. 58

Steering Handle Friction (H Type) ........................................

. 59

Remote Control Lever Friction .............................................

. 59

Water Separator ......................................................................

. 60

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

. 60

Other Checks ..........................................................................

. 62

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

. 63

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

. 63

Fuel Priming ...........................................................................

. 65

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

. 66

H Type ................................................................................

. 66

R Type ................................................................................

. 69

R1 Type ..........................................................................

. 69

R2, R3 Type ...................................................................

. 73

Emergency Starting ................................................................

. 77

8. OPERATION .............................................................................

Brake-in Procedure ................................................................

. 82

. 82

Gear Shifting ..........................................................................

. 83

H Type ................................................................................

. 83

R1 Type ..............................................................................

. 84

R2 Type ..............................................................................

. 85

R3 Type ..............................................................................

. 86

Steering ..................................................................................

. 87

H Type ................................................................................

. 87

R Type ................................................................................

. 87

CONTENTS

Cruising ..................................................................................

. 88

H Type ................................................................................

. 88

R Type ................................................................................

. 90

Trimming the Motor ..............................................................

. 92

Trim Meter (equipped type or optional equipment) ..............

. 95

Tilting the Motor ....................................................................

. 96

Moorage .................................................................................

. 97

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

. 98

Manual Relief Valve ..............................................................

. 99

Trim Tab Adjustment ..........................................................

. 100

Motor Protection System .....................................................

. 101

〈 Engine Oil Pressure, Overheat, Water Contamination

PGM-FI and ACG Warning Systems 〉 ..........................

. 101

〈 Over-rev Limiter 〉 ......................................................

. 107

〈 Anode 〉 .......................................................................

. 107

Shallow Water Operation ....................................................

. 108

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

. 109

Emergency Engine Stop

Normal Engine Stop

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

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

. 109

. 110

H Type ..............................................................................

. 110

R Type ..............................................................................

. 111

10. TRANSPORTING ...................................................................

. 113

Fuel Line Disconnection ......................................................

. 113

Transporting .........................................................................

. 113

Trailering ..............................................................................

. 114

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

. 115

5

CONTENTS

12. MAINTENANCE ....................................................................

. 116

Tool Kit and Emergency Parts .............................................

. 117

Maintenance Schedule

Engine Oil

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

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

. 118

. 120

Spark Plugs ..........................................................................

. 122

Lubrication ...........................................................................

. 125

Water Separator ...................................................................

. 127

Fuel Filter .............................................................................

. 130

Fuel Tank and Tank Filter (equipped type) .........................

. 132

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

. 133

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

. 134

Fuse ......................................................................................

. 136

ACG Fuse .............................................................................

. 137

Propeller ...............................................................................

Submerged Motor ................................................................

. 138

. 139

13. STORAGE ...............................................................................

. 140

Vapor Separator Draining ....................................................

. 141

Battery Storage .....................................................................

. 142

Outboard Motor Position .....................................................

. 143

14. TROUBLESHOOTING ...........................................................

. 144

15. SPECIFICATIONS ..................................................................

. 146

16. MAJOR Honda DISTRIBUTOR ADDRESSES IN

EUROPE ..............................................................................

. 149

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

. 152

WIRING DIAGRAM ......................................

. 155, Inside back cover

6

SAFETY INFORMATION

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

Operator Responsibility

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

Read and understand the

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

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

Gasoline is extremely flammable and is explosive under certain conditions.

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

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

Do not overfill the fuel tank.

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

1.

SAFETY

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

7

SAFETY

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

Understand the use of all controls.

Do not exceed the boat manufacturer’s power recommendation, and be sure that the outboard motor is properly mounted.

Never permit anyone to operate the outboard motor without proper instruction.

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

Do not attempt to modify the outboard motor.

Always wear a life-jacket when on board.

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

Do not remove any guards, labels, shields, covers or safety devices; they are installed for your safety.

Stop the engine immediately if anyone falls overboard.

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

Attach the emergency stop switch lanyard securely to the operator.

The engine and exhaust system become very hot during operation and remain hot for a while after stopping. Contact with hot engine components can cause burns and may ignite some materials.

Avoid touching a hot engine or exhaust system.

Allow the engine to cool before performing maintenance or transporting.

8

Carbon Monoxide Poisoning

Hazard

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

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

SAFETY

9

2.

SAFETY LABEL LOCATIONS

These labels are in the locations shown.

They warn you of potential hazards that can cause serious injury.

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

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

READ OWNER’S MANUAL

10

FUEL TANK

(equipped type)

FUEL CAUTION

SAFETY LABEL LOCATIONS

11

SAFETY LABEL LOCATIONS

CE mark location

[U and W types only]

12

CE MARK

BF75D:

BF90D:

Manufacturer and address

Dry weight

(with propeller, without battery cable)

Manufacturer and address

Dry weight

(with propeller, without battery cable)

[H (Tiller Handle) type]

ENGINE COVER

FIXING LEVER

(front)

TILLER

HANDLE

STERN

BRACKET

MANUAL

RELIEF VALVE

ANODE

3.

COMPONENT IDENTIFICATION

ENGINE

COVER

OIL LEVEL

DIPSTICK

ENGINE COVER

FIXING LEVER

(rear)

POWER TILT

SWITCH

IDLE PORT

COOLING

WATER

CHECK

HOLE

ANODE

(each side)

TRIM TAB

FLUSH PORT

CONNECTOR

ENGINE OIL

DRAIN BOLT

EXHAUST PORT/WATER

OUTLET PORT

PROPELLER

(optional equipment)

ANTICAVITATION

PLATE

OIL FILLER CAP

TILT LOCK

LEVER

FRAME SERIAL

NUMBER

GEAR OIL

LEVEL PLUG

COOLING WATER

INTAKE PORT

(each side)

GEAR OIL DRAIN BOLT

13

COMPONENT IDENTIFICATION

TILLER HANDLE

INDICATORS

(Oil pressure, Overheat,

ACG, PGM-FI)

EMERGENCY STOP

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

SHIFT LEVER

THROTTLE FRICTION

FIXING DIAL

POWER TRIM/TILT

SWITCH

THROTTLE GRIP

14

ENGINE

SWITCH

STEERING FRICTION

ADJUSTING KNOB

COMPONENT IDENTIFICATION

[R (Remote Control) type]

ENGINE COVER

FIXING LEVER

(front)

STERN

BRACKET

MANUAL

RELIEF VALVE

ANODE

ENGINE

COVER

OIL LEVEL

DIPSTICK

ENGINE COVER

FIXING LEVER

(rear)

POWER TILT

SWITCH

IDLE PORT

COOLING

WATER

CHECK

HOLE

ANODE

(each side)

FLUSH PORT

CONNECTOR

ENGINE OIL

DRAIN BOLT

TRIM TAB

EXHAUST PORT/WATER

OUTLET PORT

PROPELLER

(optional equipment)

ANTICAVITATION

PLATE

OIL FILLER CAP

TILT LOCK

LEVER

FRAME SERIAL

NUMBER

GEAR OIL

LEVEL PLUG

COOLING WATER

INTAKE PORT

(each side)

GEAR OIL DRAIN BOLT

15

COMPONENT IDENTIFICATION

REMOTE CONTROL BOX

(equipped type or optional equipment)

SIDE-MOUNT TYPE (R1 type)

REMOTE

CONTROL LEVER NEUTRAL RELEASE

LEVER

OIL PRESSURE

INDICATOR

OVERHEAT

INDICATOR

POWER

TRIM/TILT

SWITCH

FAST IDLE LEVER

PANEL-MOUNT TYPE (R2 type)

REMOTE

CONTROL LEVER

NEUTRAL RELEASE

LEVER

POWER TRIM/TILT

SWITCH

SPARE

EMERGENCY STOP

SWITCH CLIP

BUZZER

(inside)

ENGINE SWITCH

EMERGENCY STOP

SWITCH

FAST IDLE BUTTON

CONTROL LEVER

FRICTION ADJUSTER

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

16

TOP-MOUNT TYPE (R3 type)

(SINGLE MOTOR TYPE)

REMOTE CONTROL LEVER

COMPONENT IDENTIFICATION

(DUAL MOTOR TYPE)

REMOTE CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

POWER TRIM/TILT

SWITCH (LEFT)

POWER

TRIM/TILT

SWITCH

FAST IDLE BUTTON

CONTROL PANEL (optional equipment)

(for PANEL-MOUNT, TOP-MOUNT SINGLE type)

OIL PRESSURE INDICATOR

OVERHEAT INDICATOR

FAST IDLE BUTTON

(for TOP-MOUNT DUAL type)

BUZZER

ENGINE

SWITCH

EMERGENCY

STOP SWITCH

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

17

COMPONENT IDENTIFICATION

INDICATOR PANEL

(standard equipment)

ACG INDICATOR

PGM-FI INDICATOR

18

[Common]

FUEL TANK

(equipped type)

FUEL TANK TUBE

ASSEMBLY

(equipped type)

PRIMING BULB

COMPONENT IDENTIFICATION

FUEL GAUGE

VENT KNOB

FUEL TUBE ASSEMBLY

(equipped type)

FUEL LINE JOINT

(fuel tank side)

FUEL FILLER CAP

PRIMING BULB

FUEL LINE JOINT

(motor side)

FUEL LINE JOINT

(motor side)

19

COMPONENT IDENTIFICATION

TACHOMETER (equipped type or optional equipment) TRIM METER (equipped type or optional equipment)

DIGITAL TACHOMETER (optional equipment: R type) DIGITAL SPEEDOMETER (optional equipment: R type)

20

Engine Switch (Ignition Switch)

O N

S T A R T

O F F

ENGINE SWITCH

(IGNITION SWITCH)

SHIFT

LEVER

4.

CONTROLS AND FEATURES (H type)

NEUTRAL Shift Lever

FORWARD

NEUTRAL

REVERSE

SHIFT

LEVER

START ON OFF

This tiller handle is equipped with an automotive type ignition switch.

Key positions:

START:

ON:

OFF: to start the engine.

to run the engine after starting.

to stop the engine

(IGNITION OFF).

NEUTRAL

Do not leave the engine switch

(ignition switch) ON (key in ON position) when the engine is not running as the battery will discharge.

The starter motor will not work unless the shift lever is in the

NEUTRAL position.

FORWARD REVERSE

NEUTRAL

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

There are the three positions for the shift lever.

FORWARD:

NEUTRAL:

REVERSE:

The boat moves ahead.

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

The boat reverses.

21

CONTROLS AND FEATURES (H type)

Throttle Grip

THROTTLE

INDICATOR

Throttle Friction Adjuster

THROTTLE FRICTION

ADJUSTER

RELEASE

THROTTLE GRIP

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

FAST SLOW

START

The curve on the grip indicates the engine speed.

FIX

THROTTLE GRIP

The throttle friction adjuster adjusts resistance to throttle grip rotation.

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

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

22

Emergency Stop Switch

EMERGENCY STOP SWITCH

CONTROLS AND FEATURES (H type)

Emergency Stop Switch Lanyard/

Clip

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP SWITCH

Press the emergency stop switch to stop the engine.

E

S

M

W I

E R

T

G

C H

E N

L

C

A

Y

N

S

Y

T

A

O

R

P

R D

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

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

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

EMERGENCY STOP

SWITCH CLIP

E M E R G E N C Y

S

L

T

A

O

N

P

Y

S

A

W

R

I

D

T C H

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

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

23

CONTROLS AND FEATURES (H type)

Steering Friction Adjusting Knob

STEERING FRICTION

ADJUSTING KNOB

T O D E C R E A S E

F R I C T I O N

SPARE EMERGENCY STOP

SWITCH CLIP

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

A spare emergency stop switch clip is provided in the tool bag (see page

117 ).

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

24

T O I N C R E A S E

F R I C T I O N

Use the steering friction adjusting knob to adjust the tiller handle friction. Turning clockwise increases friction and turning it counterclockwise decreases friction.

CONTROLS AND FEATURES (R type)

Remote Control Lever (R1 type)

REMOTE CONTROL LEVER

NEUTRAL RELEASE LEVER

FORWARD

NEUTRAL

REVERSE

FORWARD

30°

NEUTRAL

30°

SHIFT SHIFT

REVERSE

M I N I M U M M I N I M U M

T H R O T T L E O P E N I N G

T H R O T T L E O P E N I N G

MAXIMUM

MAXIMUM

REMOTE CONTROL LEVER

Shifting gear into forward, reverse, or neutral and the engine speed adjustment can be performed with the remote control lever.

It is necessary to pull up the neutral release lever to operate the remote control lever.

FORWARD:

Moving the lever to the FORWARD position (i.e. approximately 30° from the NEUTRAL position) engages the gear into forward. Moving the lever further from the FORWARD position will increase the throttle opening and the boat forward speed.

NEUTRAL:

Engine power is cut off from the propeller.

REVERSE:

Moving the lever to the REVERSE position (i.e. approximately 30° from the NEUTRAL position) engages the gear into reverse. Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed.

25

CONTROLS AND FEATURES (R type)

Remote Control Lever (R2 type)

REMOTE CONTROL LEVER

NEUTRAL RELEASE LEVER

FORWARD

FORWARD

M I N I M

T H R O T T L E O P E N I N G

35°

NEUTRAL

SHIFT

35°

SHIFT

U M

REVERSE

M I N I M U M

T H R O T T L E

O P E N I N G

NEUTRAL

MAXIMUM

MAXIMUM

REMOTE CONTROL LEVER

REVERSE

Shifting gear into forward, reverse, or neutral and the engine speed adjustment can be performed with the remote control lever.

It is necessary to pull up the neutral release lever to operate the remote control lever.

FORWARD:

Moving the lever to the FORWARD position (i.e. approximately 35° from the NEUTRAL position) engages the gear into forward. Moving the lever further from the FORWARD position will increase the throttle opening and the boat forward speed.

NEUTRAL:

Engine power is cut off from the propeller.

REVERSE:

Moving the lever to the REVERSE position (i.e. approximately 35° from the NEUTRAL position) engages the gear into reverse. Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed.

26

CONTROLS AND FEATURES (R type)

Remote Control Lever (R3 type)

(SINGLE TYPE)

REMOTE

CONTROL LEVER

(DUAL TYPE)

FORWARD

FORWARD

NEUTRAL

FORWARD

T H R O T T L E

O P E N I N G

M I N I

35°

NEUTRAL

35°

REVERSE

SHIFT

M U M

SHIFT

T H R O T T L E

O P E N I N G

M I N I M U M

NEUTRAL

MAXIMUM

REVERSE

REVERSE

REMOTE CONTROL LEVERS

Shifting gear into forward, reverse, or neutral and the engine speed adjustment can be performed with the remote control lever.

FORWARD:

Moving the lever to the FORWARD position (i.e. approximately 35° from the NEUTRAL position) engages the gear into forward. Moving the lever further from the FORWARD position will increase the throttle opening and the boat forward speed.

MAXIMUM

REMOTE CONTROL LEVER

REVERSE:

Moving the lever to the REVERSE position (i.e. approximately 35° from the NEUTRAL position) engages the gear into reverse. Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed.

NEUTRAL:

Engine power is cut off from the propeller.

27

CONTROLS AND FEATURES (R type)

Neutral Release Lever

(R1 type)

REMOTE CONTROL LEVER

Engine Switch (Ignition Switch)

(R1 type)

ON

START

OFF

ENGINE

SWITCH

(R2, R3 types)

ON

OFF

START

ON

NEUTRAL

RELEASE LEVER

(R2 type)

REMOTE CONTROL LEVER

NEUTRAL

RELEASE LEVER

The neutral release lever is set on the remote control lever to prevent an accidental operation of the remote control lever.

The remote control lever does not operate unless it is moved while pulling the neutral release lever up.

28

This remote control is equipped with an automotive type ignition switch.

On the side-mount type (R1 type), the engine switch locates on your side near the remote control box.

On the panel-mount type (R2 type) and the top-mount type (R3 type), the engine switch locates at the center of the control panel.

Key positions:

START: to start the engine.

ON:

OFF: to run the engine after starting.

to stop the engine

(IGNITION OFF).

OFF START

ENGINE SWITCH

Do not leave the engine switch

(ignition switch) ON (key in ON position) when the engine is not running as the battery will discharge.

The starter motor will not work unless the remote control lever is in the NEUTRAL position, and the clip is in the emergency stop switch.

Fast Idle Lever (R1 type)/Fast Idle

Button (R2, R3 types)

The fast idle lever/fast idle button is only needed for starting carbureted outboard models. The BF75D and

BF90D models use programmed fuel injection so, this lever will not be needed for starting.

After the engine starts and if the outside temperature is below 5° C (41

° F), the fast idle lever/fast idle button can be used to accelerate engine warm up.

CONTROLS AND FEATURES (R type)

〈 Fast Idle Lever 〉

(R1 type)

REMOTE

CONTROL LEVER

NEUTRAL

MAXIMUM

FAST IDLE

〈 Fast Idle Button 〉

(R2 type)

NEUTRAL

FORWARD

REVERSE

LOWEST

POSITION

FAST IDLE LEVER

The fast idle lever will not move unless the remote control lever is in the NEUTRAL position. Conversely, the remote control lever will not move unless the fast idle lever is in the lowest position.

Lower the fast idle lever to the lowest position to decrease the fast idle.

P u l l u p

REMOTE

CONTROL

LEVER

NEUTRAL

RELEASE

LEVER

Push

FAST IDLE BUTTON

Pushing the fast idle button, turn the remote control lever forward. Keep turning the lever forward. The throttle opens and the engine speed increases after the lever passed the shift point.

Note that the gearshift mechanism does not function when the fast idle button is pushed once and then released after the remote control lever is moved.

The control lever does not operate unless the neutral release lever is pulled.

29

CONTROLS AND FEATURES (R type)

〈 Fast Idle Button 〉

(R3 type)

NEUTRAL

FORWARD

REVERSE

Emergency Stop Switch

(R1 type)

Emergency Stop Switch Lanyard/

Clip

EMERGENCY STOP

SWITCH LANYARD

REMOTE

CONTROL

LEVER

Push

FAST IDLE BUTTON

Use the fast idle button and the remote control lever to adjust the engine speed without gearshift when warming up the engine.

Pushing the fast idle button, turn the remote control lever forward. Keep turning the lever forward. The throttle opens and the engine speed increases after the lever passed the shift point.

Note that the gearshift mechanism does not function when the fast idle button is pushed once and then released after the remote control lever is moved.

30

EMERGENCY STOP SWITCH

(R2, R3 types)

EMERGENCY STOP SWITCH

Press the emergency stop switch to stop the engine.

EMERGENCY STOP SWITCH CLIP

The emergency stop switch lanyard is provided to stop the engine immediately in the event the operator should fall overboard or away from the controls.

The emergency stop switch clip must be engaged with the emergency stop switch or the engine will not start.

When the emergency stop switch clip becomes disengaged with the emergency stop switch the engine will stop immediately.

CONTROLS AND FEATURES (R type)

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

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

(R1 type)

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY STOP

SWITCH CLIP

(R2, R3 types)

EMERGENCY STOP SWITCH

Spare Emergency Stop Switch Clip

(R1 type)

SPARE EMERGENCY

STOP SWITCH CLIP

A spare emergency stop switch clip is provided on the remote control box.

(All types)

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

SPARE EMERGENCY

STOP SWITCH CLIP

A spare emergency stop switch clip is provided in the tool bag (see page

117 ).

31

CONTROLS AND FEATURES (Common)

(R1 type) Oil Pressure Indicator/Buzzer

The oil pressure indicator turns off and the buzzer sounds when the oil level is low and/or the engine lubrication system is faulty.

The engine speed slows down gradually this time.

(H type)

OIL PRESSURE

INDICATOR

(GREEN)

BUZZER

(GREEN)

(R2, R3 types)

(GREEN)

OIL PRESSURE

INDICATOR

Overheat Indicator/Buzzer

The overheat indicator turns on and the buzzer sounds when the engine cooling circuit is faulty. The engine speed slows down this time.

(H type)

(RED)

OVERHEAT

INDICATOR

OIL PRESSURE

INDICATOR

(internal organs the buzzer)

BUZZER

(internal organs the buzzer)

32

(R1 type)

(R2, R3 types)

(RED)

OVERHEAT

INDICATOR

(RED)

BUZZER

CONTROLS AND FEATURES (Common)

ACG Indicator/Buzzer

The ACG indicator turns on and the buzzer sounds when the charging system is faulty.

(H type) (R type)

ACG INDICATOR

OVERHEAT

INDICATOR

ACG INDICATOR

(internal organs the buzzer)

(indicator panel)

BUZZER

33

CONTROLS AND FEATURES (Common)

PGM-FI Indicator/Buzzer

The PGM-FI indicator turns on and the buzzer sounds when the engine control system is faulty.

(H type) (R type)

(indicator panel)

PGM-FI

INDICATOR

(internal organs the buzzer)

PGM-FI INDICATOR

(RED)

Water Separator Buzzer

The water separator buzzer sounds when water has accumulated in the water separator.

WATER SEPARATOR

34

CONTROLS AND FEATURES (Common)

Power Trim/Tilt Switch

Power Trim

Press the power trim/tilt switch on the remote control lever to adjust the motor trim angle of − 4° to 16° to maintain proper boat trim. The power trim/tilt switch can be operated while the boat is under way or while stopped.

By using the power trim/tilt switch the operator can change the trim angle of the motor to achieve maximum boat acceleration, speed, stability and maintain optimum fuel consumption.

The motor trim angle of − 4° to 16° is the angle when the outboard motor is installed on the boat at 12° .

(H type) (R3 type)

(SINGLE TYPE)

POWER TRIM/TILT

SWITCH

POWER TRIM/

TILT SWITCH

(R1 type)

REMOTE

CONTROL

LEVER

(DUAL TYPE)

POWER TRIM/TILT SWITCH

(LEFT) (RIGHT)

POWER

TRIM/TILT

SWITCH

REMOTE CONTROL

LEVER

(R2 type)

POWER TRIM/TILT SWITCH

REMOTE CONTROL LEVER

REMOTE

CONTROL

LEVER

Excessive trim/tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump.

35

CONTROLS AND FEATURES (Common)

Trim Meter

(equipped type or optional equipment)

Power Tilt Switch (motor pan)

68°

12°

TILT

ANGLE 0°

16°

− 4°

(VERTICAL LINE)

T R I M A N G L E

( w h e n t r a n s o m a n g l e i s 1 2 ° )

Power Tilt

Press the power trim/tilt switch to adjust the motor tilt angle of 16° to

68° .

By using the power trim/tilt switch the operator can change the tilt angle of the motor for shallow water operation, beaching, launching from a trailer, or mooring.

Please tilt up simultaneously, when you mount the dual type outboard motor.

TRIM METER

The trim meter has a range of − 4° to

16° and indicates the trim angle of the outboard motor. Refer to the trim meter when using the power trim/tilt switch to achieve proper boat performance.

The motor trim angle of − 4° to 16° is the angle when the outboard motor is installed on the boat at 12° .

POWER TILT SWITCH

The power tilt switch located on the motor pan is a convenience switch for tilting the motor for trailering, or preforming outboard maintenance.

This power tilt switch should only be operated with the boat being stopped and motor off.

36

CONTROLS AND FEATURES (Common)

Tilt Lock Lever Manual Relief Valve

P O W E R

( T o f i x )

M A N U A L

( T o r e l e a s e )

MANUAL RELIEF VALVE

If the power trim/tilt switch will not tilt the outboard motor, the motor can be manually tilted up or down by opening the manual relief valve. To tilt the outboard motor manually, turn the manual relief valve under the left stern bracket no more than 1 or 2 turns counterclockwise using a screwdriver.

After tilting the motor, turn the manual relief valve clockwise securely.

Check that no person is under the outboard motor before carrying out this operation because if the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

The manual relief valve must be tightened securely before operating the motor or the motor could tilt up when operating in reverse.

L O C K

F R E E

T I L T L O C K L E V E R

Use the tilt lock lever to raise the motor and lock it in the position when the boat is moored or anchored for a long time.

Tilt the motor as far as it goes and move the lock lever in the locking direction.

37

CONTROLS AND FEATURES (Common)

Trim Tab

GEAR CASE GROMMET

Anode

TRIM TAB

TIGHTENING BOLT

If the steering wheel/handle is pulled to the side while running at full speed, adjust the trim tab so that the boat runs straight ahead.

Remove the gear case grommet.

Loosen the tightening bolt and turn the trim tab right or left to adjust (see page 100 ).

ANODE

(each side)

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

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

ANODE

(stern bracket)

38

Cooling Water Intake Port

CONTROLS AND FEATURES (Common)

Cooling Water Check Hole

COOLING WATER CHECK HOLE

COOLING WATER INTAKE PORT

(each side)

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

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

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

39

CONTROLS AND FEATURES (Common)

Engine Cover Fixing Lever

(Front/Rear)

ENGINE COVER

FIXING LEVER

(front/rear)

Tachometer

(equipped type or optional equipment)

Digital Tachometer

(optional equipment:R type)

U N L O C K

L O C K

Latch/unlatch the engine cover fixing lever to install or remove the engine cover.

TACHOMETER

The tachometer shows the engine speed in revolutions per minute.

Digital Tachometer includes the following functions.

Tachometer

Hour Meter

Trim Meter

Oil Pressure Indicator

Overheat Indicator

ACG Indicator

PGM-FI Indicator

Refer to the Operation Guide included with each Digital

Tachometer for operation information.

40

Digital Speedometer

(optional equipment:R type)

CONTROLS AND FEATURES (Common)

Fuel Filler Cap (equipped type)

(with vent knob and Fuel Gauge)

VENT KNOB

C L O S E

O P E N

Digital Speedometer includes the following functions.

Speedometer

Fuel Level Meter

Volt Meter

Tripmeter

Fuel Integration Meter

Fuel Economy Meter

Fuel Flow Meter

Water Separator Indicator

Refer to the Operation Guide included with each Digital

Speedometer for operation information.

FUEL

GAUGE

FUEL FILLER CAP

The fuel filler cap vent knob controls air entering and leaving the fuel tank.

The fuel gauge is part of the fuel filler cap, and indicates the fuel level in the tank.

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

Turn the vent knob clockwise and close it securely before transporting or storing the fuel tank.

41

CONTROLS AND FEATURES (Common)

Fuel Line Connector And Joint

(equipped type)

FUEL LINE CONNECTOR

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

(FUEL TANK SIDE)

H O S E P L U G

42

F U E L H O S E

F U E L L I N E

J O I N T

H O S E C L A M P

(OUTBOARD MOTOR SIDE)

5.

INSTALLATION

Transom Height

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

We recommend that the outboard motor be installed by an authorized

Honda outboard motor dealer.

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

Optional Parts)/equipments installation and operation.

Applicable Boat

Select the boat suitable for the engine power.

Engine power:

BF75D: 55.2 kW (75 PS)

BF90D: 66.2 kW (90 PS)

Power recommendation is indicated on most of the boats.

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

T

Type:

L:

X:

T (Motor Transom

Height)

〈 when transom angle is 12° 〉

537 mm (21.1 in)

664 mm (26.1 in)

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

43

INSTALLATION

Location Installation Height

BOAT TRANSOM

HEIGHT

IDLE

PORT

IDLE

PORT

150 mm

(5.9 in) or more

±

±

25 mm

( 1 in)

WATER LEVEL

CENTER LINE

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

TRANSOM HEIGHT

ANTICAVITATION PLATE

The anticavitation plate of the outboard motor should be ± 25 mm

( 1 in) below the bottom of the boat.

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

FULLY

TRIM/TILT

DOWN

The water level must be at least

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

Adverse effect to the engine can occur if the installation position of the outboard motor is too low.

Trim/tilt down the outboard motor with the boat fully loaded and stop the engine. Check that the idle port is 150 mm (5.9 in) or more above the water level.

44

Outboard Motor Installation

BOLT

(12 119 mm) (4)

STERN BRACKET

Standard torque:

55 N·m (5.6 kgf·m , 41 lbf·ft)

The standard torque is given just as a guideline. Torque of the nut can be different according to the material of the boat. Consult with an authorized

Honda outboard motor dealer.

WASHER (8)

NUT (8)

ENGINE

HANGER (2)

INSTALLATION

WASHER (4)

1.

2.

Apply the silicone sealant

(Three Bond 1216 or equivalent) to the outboard motor mounting holes.

Set the outboard motor on the boat and secure with the bolts, washers, and nuts.

Install the outboard motor securely. Loosely mounted outboard motor can result in accidental loss of the motor and damage and injury to the equipment and personnel.

Before installing the outboard motor on the boat, hang the outboard motor with the hoist or equivalent devise by attaching the two engine hangers to the outboard.

Use the hoist which allowable load is

250 kg (551 lbs) or above.

45

INSTALLATION

Motor Angle Inspection (Cruising)

INCORRECT

CAUSES BOAT TO ‘‘SQUAT’’

INCORRECT

CAUSES BOAT TO ‘‘PLOW’’

CORRECT

GIVES MAXIMUM PERFORMANCE

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

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

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

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

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

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

46

Battery Connections

Use a battery which has CCA

(COLD CRANKING AMPERES)

582A at − 18° C (0° F) and a reserve capacity 229 minutes (12V

55Ah/5HR or 12V 65Ah/20HR) or more specifications.

The battery is an optional part (i.e.

part to be purchased separately from the outboard motor).

INSTALLATION

Batteries produce explosive gases: If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid. Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.

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

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

POISON: Electrolyte is poison.

ANTIDOTE:

− External: Flush thoroughly

− with water.

Internal: Drink large quantities of water or milk.

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

KEEP OUT OF REACH OF

CHILDREN.

To protect the battery from mechanical damage and to prevent the battery from falling or tipping over, the battery must be:

Installed in the correct size corrosion-resistant battery box.

Properly secured in the boat.

Secured in a location free from direct sunlight and water spray.

Secured away from the fuel tank to avoid potential sparks near the fuel tank.

47

INSTALLATION

RED

BLACK

Connect the battery cables:

1.

Connect the cable with the red

2.

terminal cover to the positive ( ) terminal of the battery.

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

When the two outboard motors are mounted on a boat, connect a battery to the respective right and left outboard motors.

48

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

Unless the cables are properly connected to the terminals, the starter motor may fail to operate normally.

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

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

Do not place the fuel tank near the battery.

Battery cable extension:

Extending the original battery cable will cause the battery voltage to drop due to the increased length of the cable and number of connections. This voltage drop may cause the buzzer to sound momentarily when engaging the starter motor and may prevent the outboard from starting. If the outboard starts and the buzzer sounds momentarily, there may be barely sufficient voltage reaching the engine.

INSTALLATION

Remote Control Installation

(equipped type or optional equipment)

Improperly installed steering system, remote control box, and remote control cable, or installing those of the different types could cause unpredictable accident.

Consult an authorized Honda outboard motor dealer for proper installation.

The control box is available in three types as shown.

Select the most suitable control box for your outboard motor considering the installation position, operationability, etc. of the control box.

See an authorized Honda outboard motor dealer for further information.

SIDE-MOUNT

TYPE CONTROL BOX

PANEL-MOUNT TYPE CONTROL

BOX AND SWITCH PANEL

TOP-MOUNT TYPE CONTROL BOX

AND SWITCH PANEL

(FOR SINGLE MOTOR TYPE)

TOP-MOUNT TYPE CONTROL BOX

AND SWITCH PANEL

(FOR DUAL MOTOR TYPE)

49

INSTALLATION

〈 Remote Control Box Location 〉 〈 Remote Control Cable Length 〉

REMOTE

CONTROL BOX

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

CABLE

Do not bend the remote control cable as sharp as its route diameter is 300 mm (11.8 in.) or less, or it affects the service life of the cable and the remote control lever operation.

Install the remote control box in the position where is easy to operate the remote control lever and switches.

Be sure that there are no obstacles on the route of the control cable.

The control box position of the R2 type and the R3 type should be determined in the same manner.

Measure the distance from the control box to the outboard motor along the cable routing.

Recommended cable length is 300 −

450 mm (11.8 17.7 in.) longer than the measured distance.

Set the cable along the predetermined route and be sure that it is long enough to the route.

Connect the cable to the engine and be sure it is not kinked, bent sharp, pulled taut, or interfered while steering.

50

Propeller Selection

Select the adequate propeller so that the engine speed at full throttle is

BF75D: 5,000 min (rpm) to 6,000 min (rpm). BF90D: 5,300 min

(rpm) to 6,300 min (rpm) when the boat is loaded.

Engine speed varies according to the propeller size and the boat condition.

Use of the outboard motor outside the full throttle speed range will adversely affect the engine and cause serious problem. Use of the correct propeller assures powerful acceleration, top speed, excellency in terms of economy and cruising comfort, and it assures longer engine life as well.

Consult with your authorized Honda outboard motor dealer for proper propeller selection.

INSTALLATION

51

6.

PRE-OPERATION CHECKS

BF75D/90D is 4-stroke, water cooled outboard motor which uses unleaded regular gasoline for fuel. It also requires the engine oil. Check the following before operating the outboard motor.

Engine Cover Removal/Installation

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

LATCH

(front/rear)

ENGINE COVER

FIXING LEVER

(front/rear)

To remove, raise the front and rear engine cover fixing levers and remove the engine cover.

To install, set the engine cover, hook the front and rear latches, and push down the front and rear engine cover fixing levers.

Do not operate the outboard motor without the engine cover.

Exposed moving parts can cause injury.

52

Engine Oil

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

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

〈 Recommended oil 〉

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

Service Classification SG, SH or SJ.

Motor oils classified SG, SH or SJ will show this designation on the container.

SAE 10W-30 is recommended for general use.

PRE-OPERATION CHECKS

〈 Inspection and Refilling 〉

AMBIENT TEMPERATURE

UPPER

LEVEL

MARK

LOWER

LEVEL

MARK

OIL LEVEL DIPSTICK

1.

2.

3.

Position the outboard motor vertically, and remove the engine cover.

Remove the oil level dipstick and wipe with a clean rag.

Reinsert the dipstick all the way in, then pull it out and read the level.

If near or below the lower level mark, remove the oil filler cap and fill to the upper level mark with the recommended oil. Tighten the oil filler cap and install the dipstick securely. Do not overtighten.

53

PRE-OPERATION CHECKS

When the engine oil is contaminated or discolored, replace with the fresh engine oil (see page 120 for replacement interval and procedure).

Oil filler cap removal (Unlock):

1) Turn the oil filler cap 90° counterclockwise so the lug of the

2) cap sets horizontally.

Pull the cap to remove it.

Oil filler cap installation (Lock):

1) Insert the oil filler cap into the oil filler port with the lug being set

2) horizontally.

Turn the oil filler cap 90° clockwise so the lug of the cap is in line with the rib of the ACG cover. (It should click.)

OIL FILLER CAP

R i b o f t h e A C G c o v e r

4.

Install the engine cover and lock it securely.

Do not overfill the engine oil.

Check the engine oil after refilling.

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

54

Fuel

(Fuel Tank equipped type)

FUEL FILLER

CAP

UPPER LEVEL

FUEL GAUGE

Check the fuel gauge and refill the tank to the upper level mark if necessary. Do not fill the fuel tank above the UPPER level mark.

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

Fuel tank capacity (separate tank):

25 (6.6 US gal , 5.5 Imp gal)

(Using the fuel tank mounted on the boat)

Check the fuel level and refill if neccessary. Do not fill the fuel tank above the UPPER LIMIT.

Refer to the boat manufacturer’s instructions.

PRE-OPERATION CHECKS

Use unleaded gasoline with a

Research Octane Number of 91 or higher (a Pump Octane Number of

86 or higher). Use of leaded gasoline may cause damage to the engine.

Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust or water in the fuel tank.

55

PRE-OPERATION CHECKS

Gasoline is extremely flammable and is explosive under certain conditions.

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

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

Do not overfill the fuel tank

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

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

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

KEEP OUT OF REACH OF

CHILDREN.

GASOLINE CONTAINING

ALCOHOL

If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by Honda. There are two types of gasohol : one containing ethanol, and the other containing methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors.

Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of the fuels containing methanol since evidence of their suitability is as yet incomplete.

Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol, if it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol.

56

PRE-OPERATION CHECKS

Propeller and Cotter Pin

Inspection

COTTER PIN

The propeller blades are thin and sharp. Careless handling of the propeller can result in injury.

When checking the propeller:

Remove the emergency stop switch clip to prevent an accidental start of the engine.

Wear heavy gloves.

Propeller rotates rapidly while cruising. Before starting the engine, check the propeller blades for damage and deformation and replace if necessary.

Obtain a spare propeller for the event of an unpredictable accident while cruising. If no spare propeller is available, return to the pier at low speed and replace (see page 138 ).

Consult an authorized Honda outboard motor dealer for propeller selection.

Keep the spare washer, castle nut and cotter pin with you on your boat.

PROPELLER

Engine speed varies according to the propeller size and the boat condition.

Use of the outboard motor outside the full throttle speed range will adversely affect the engine and cause a serious problem. Use of the correct propeller assures powerful acceleration, top speed, excellency in terms of economy and cruising comfort, and it assures longer engine life as well.

Consult with your authorized Honda outboard motor dealer for proper propeller selection.

CASTLE NUT

1.

2.

3.

Check the propeller for damage, wear, or deformation.

Replace whenever the propeller is faulty.

Check whether the propeller is installed properly.

Check the cotter pin for damage.

57

PRE-OPERATION CHECKS

Tiller Handle Height/Angle

Adjustment (H type)

The tiller handle height and angle can be adjusted to three positions by changing the installation direction of the height adjustment block. Select a suitable height and angle for the operator and secure the block.

〈 Height/Angle Adjustment

Procedure 〉

1.

Raise the tiller handle and remove the 8 × 28 mm flange bolt and the

2.

height adjustment block.

Pull down the tiller handle.

Determine the height adjustment block installation direction and secure the block with the 8 × 28 mm flange bolt.

HANDLE ANGLE: 7°

HANDLE ANGLE:

21°

Install the height adjustment block so that the selected angle of the tiller handle is in this position.

8 × 28 mm

FLANGE BOLT

HEIGHT ADJUSTMENT

BLOCK

296 mm

(11.7 in)

HANDLE ANGLE: 7°

HANDLE ANGLE: 13°

58

359 mm

(14.1 in)

HANDLE ANGLE: 13°

433 mm

(17.0 in)

HANDLE ANGLE: 21°

HEIGHT

Reference point

Steering Handle Friction (H type) Remote Control Lever Friction

(R1 type)

PRE-OPERATION CHECKS

(R2 type)

T o d e c r f r i c t i o n e a s e

To increase friction

To increase friction

STEERING

FRICTION

ADJUSTING

KNOB

T o i n c r e a s e f r i c t i o n

Check whether the handle moves smoothly.

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

CONTROL

LEVER

FRICTION

ADJUSTER

To decrease friction

Check whether the remote control lever moves smoothly.

Friction of the control lever can be adjusted by turning the control lever friction adjuster right or left.

To decrease friction

(R3 type)

To increase friction

CONTROL

LEVER

FRICTION

ADJUSTER

To decrease friction

CONTROL LEVER FRICTION ADJUSTER

59

PRE-OPERATION CHECKS

Water Separator Battery POSITIVE ( )

TERMINAL

WATER SEPARATOR

Water separator is located near by the engine cover fixing lever of the boat side. Check the water separator for water accumulation. Clean it or consult with an authorized Honda outboard motor dealer for clean (see page 127 ).

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

Battery Inspection

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

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

134 ).

Check that the battery cables are connected securely.

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

(see page 135 ).

60

UPPER

LEVEL

LOWER

LEVEL

Batteries produce explosive gases: If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid. Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.

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

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

POISON: Electrolyte is poison.

ANTIDOTE:

− External: Flush thoroughly with water.

− Internal: Drink large quantities of water or milk.

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

KEEP OUT OF REACH OF

CHILDREN.

PRE-OPERATION CHECKS

61

PRE-OPERATION CHECKS

Other Checks

(2)

(5) TOOL KIT

10 × 14 mm WRENCH

EMERGENCY

STARTER ROPE

SPARK PLUG WRENCH

(3) 8 × 12 mm WRENCH

18 × 19 mm

BOX WRENCH

(1)

Check the following items:

(1) The fuel hose for kinking, collapsing or a loose connection.

(2) The tiller handle for loose installation, wobble or smooth operation (H type).

The remote control lever for

(3) smooth operation (R type).

The switch for correct operation.

(4)

(5)

The stern bracket for damage.

The tool kit for missing spare parts

(6) and tools.

The anode metal for damage, looseness or excessive corrosion.

62

(2)

OIL CHECK

SCREWDRIVER

10 mm BOX WRENCH

(3)

PHILLIPS/FLAT

SCREWDRIVER

PLIERS

(4)

(6)

The anode (sacrificed metal) helps to protect the outboard motor from corrosion damage; it must be exposed directly to the water whenever the motor is in use. Replace the anode metal when it has been reduced to approximately one half of its original size.

SCREWDRIVER

HANDLE FUSE PULLER

TOOL BAG

SPARE EMERGENCY

STOP SWITCH CLIP

Parts/materials which should be installed on board:

(1) Owner’s Manual

(2)

(3)

Tool kit

Spare parts: spark plugs, engine oil, spare propeller, castle nut, washer and cotter pin.

(4) Other parts/materials required by laws/regulations.

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

Fuel Line Connection

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

Be careful not to spill fuel.

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

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

Set the fuel tank securely so that it does not move or fall down while cruising.

Position the fuel tank so the tank fuel line connector is no more than

1 m (3.3 feet) below the motor fuel line connector.

Do not place the fuel tank more than 2 m (6.6 feet) away from the motor.

Be sure that the fuel line is not kinked.

(Fuel Tank equipped type)

HOSE PLUG

FUEL TUBE

ASSEMBLY

7.

STARTING THE ENGINE

FUEL HOSE

(motor side)

BARB

HOSE CLAMP

(STAINLESS

STEEL)

ARROW

PRIMING

BULB

(OUTBOARD MOTOR SIDE)

1.

Remove the hose plug from the engine side fuel hose. Insert the fuel line joint in the engine side fuel hose and secure it with the hose clamp. Make sure the arrow mark on the priming bulb points toward the engine side.

Store the hose plug in a secure place.

FUEL

HOSE

HOSE

CLAMP

FUEL LINE

JOINT

63

STARTING THE ENGINE

FUEL LINE CONNECTOR

− To fuel tank

(FUEL TANK SIDE)

2.

Connect the fuel line to the tank.

Be sure the connector is securely latched.

O P E N

VENT KNOB (Using the fuel tank mounted on the boat)

FUEL TUBE ASSEMBLY

(equipped type)

(motor side)

FUEL HOSE

(tank side)

3.

Open the fuel cap vent knob 2 to 3 turns.

BARB

HOSE CLAMP

(stainless steel)

(FUEL TANK SIDE)

1.

2.

Remove the hose plug from the engine side fuel hose. Insert the fuel line joint into the engine side fuel hose and secure it with the hose clamp. (The procedure is the same as in the case of using a fuel tank equipped type. Refer to the previous page.)

Insert another fuel line joint up to the barb of the joint in the fuel tank side and secure it with the hose clamp (stainless steel type).

Refer to the owner’s manual for the boat.

64

Fuel Priming

ARROW

OUTLET END

(motor side)

Do not touch the priming bulb with the engine running or when tilting up the outboard motor. The vapor separator could overflow.

STARTING THE ENGINE

PRIMING BULB

INLET END

(tank side)

Hold the priming bulb so that the outlet end is higher than the inlet (so that the arrow on the priming bulb points up), and squeeze it until it feels firm, indicating that fuel has reached the motor. Check for leaks.

Be careful not to spill any fuel.

Spilled fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

65

STARTING THE ENGINE

Starting the Engine (H type)

ENGINE STOP MARK

EMERGENCY

STOP SWITCH

1.

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

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

The exhaust contains poisonous carbon monoxide.

Do not start the engine in a poor ventilation area such as in a boat house.

If the operator does not attach the emergency stop switch lanyard, and is thrown from his seat or out of the boat, the outof-control boat can seriously injure the operator, passengers, or bystanders. Always properly attach the lanyard before starting the motor.

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

SPARE EMERGENCY STOP

SWITCH CLIP

A spare emergency stop switch clip is provided in the tool bag (see page

117 ).

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

To prevent damage to the outboard from overheating, never run the engine with the propeller out of water.

66

SHIFT

LEVER

NEUTRAL

THROTTLE GRIP

STARTING THE ENGINE

ENGINE SWITCH KEY

O N

START

O F F

‘‘ ’’ MARK START

START ON

NEUTRAL

2.

Move the shift lever to the

NEUTRAL position. The engine does not start unless the shift lever is set in the NEUTRAL position.

3.

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

4.

Turn the engine 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.

67

STARTING THE ENGINE

The starter motor consumes a large amount of current. Do not therefore run it continuously for more than 5 seconds at a time. If the engine does not start within 5 seconds, wait at least 10 seconds before running the starter motor again.

Do not turn the engine switch key to the START position while the engine is running.

’’ prevents the engine from being started unless the control lever is set in the N (neutral) position even though the engine is cranked by the starting motor.

COOLING WATER

CHECK HOLE

COOLING WATER

INTAKE PORT (each side)

5.

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

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

Check to see if the screen in the cooling water intake port is obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by an authorized

Honda outboard motor dealer. Do not operate the engine until the problem has been corrected.

68

NORMAL: ON

ABNORMAL: OFF

STARTING THE ENGINE

7.

Warm up the engine as follows:

Above 5° C (41° F) run the engine for at least 3 minutes.

Below 5° C (41° F) run the engine for at least 5 minutes at approx.

2,000 min (rpm).

Failure to completely warm up the engine will result in poor engine performance.

Starting the Engine (R type)

(R1 type)

EMERGENCY

STOP SWITCH

ENGINE OIL

PRESSURE

INDICATOR

LIGHT

6.

Check to see if the oil pressure indicator light turns ON.

If it does not turn on, stop the engine and perform the following inspections.

1) Check the oil level (see page

53 ).

2) If the oil level is normal and the oil pressure indicator light does not turn ON, consult with an authorized Honda outboard motor dealer.

If the engine is not properly warmed-up before raising the engine speed, the warning buzzer and overheat indicator may activate and the engine speed will be automatically reduced.

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

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

The exhaust contains poisonous carbon monoxide.

Do not start the engine in a poor ventilation area such as in a boat house.

To prevent damage to the outboard from overheating, never run the engine with the propeller out of water.

69

STARTING THE ENGINE

1.

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

SPARE EMERGENCY

STOP SWITCH CLIP

REMOTE CONTROL LEVER

NEUTRAL

NEUTRAL

If the operator does not attach the emergency stop switch lanyard, and is thrown from his seat or out of the boat, the outof-control boat can seriously injure the operator, passengers, or bystanders. Always properly attach the lanyard before starting the motor.

A spare emergency stop switch clips are provided on the remote control box and in the tool bag (see page

117 ).

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

START

FAST IDLE LEVER

2.

3.

Set the control lever in the

NEUTRAL position.

The engine does not start unless the control lever is set in the

NEUTRAL position.

Leave the fast idle lever in the

START (fully lowered) position.

70

STARTING THE ENGINE

OFF

ON

START

The starter motor consumes a large amount of current. Do not therefore run it continuously for more than 5 seconds at a time. If the engine does not start within 5 seconds, wait at least 10 seconds before running the starter motor again.

Do not turn the engine switch key to the START position while the engine is running.

ENGINE SWITCH KEY

4.

Turn the engine 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.

’’ prevents the engine from being started unless the control lever is set in the N (neutral) position even though the engine is cranked by the starting motor.

COOLING WATER

CHECK HOLE

COOLING WATER INTAKE PORT

(each side)

5.

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

71

STARTING THE ENGINE

ENGINE OIL PRESSURE

INDICATOR LIGHT

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

Check to see if the screen in the cooling water intake port is obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by an authorized

Honda outboard motor dealer. Do not operate the engine until the problem has been corrected.

6.

Check to see if the oil pressure indicator turns ON.

If it does not turn on, stop the engine and perform the following inspections.

1) Check the oil level (see page 53 ).

2) If the oil level is normal and the oil pressure indicator light does not turn ON, consult with an authorized Honda outboard motor dealer.

72

NORMAL: ON

ABNORMAL: OFF

7.

Warm up the engine as follows:

− for at least 3 minutes.

Below 5° C (41° F) run the engine for at least 5 minutes at approx.

2,000 min (rpm).

Failure to completely warm up the engine will result in poor engine performance.

Digital Tachometer

Normal

Abnormal

If the engine is not properly warmed-up before raising the engine speed, the warning buzzer and overheat indicator may activate and the engine speed will be automatically reduced.

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

STARTING THE ENGINE

(R2, R3 types)

EMERGENCY

STOP SWITCH

CONTROL PANEL following on the right and left engines respectively.

1.

Insert the clip at one end of the emergency stop switch lanyard into the emergency stop switch.

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

Be sure to install the emergency stop switch clip to the emergency stop switch on the remote control box as well as on the control panel.

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

The exhaust contains poisonous carbon monoxide.

Do not start the engine in a poor ventilation area such as in a boat house.

To prevent damage to the outboard from overheating, never run the engine with the propeller out of water.

When the boat is mounted with the two outboard motors, perform the

If the operator does not attach the emergency stop switch lanyard, and is thrown from his seat or out of the boat, the outof-control boat can seriously injure the operator, passengers, or bystanders. Always properly attach the lanyard before starting the engine.

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

SPARE EMERGENCY

STOP SWITCH CLIP

A spare emergency stop switch clip is provided in the tool bag (see page

117 ).

73

STARTING THE ENGINE

NEUTRAL

NEUTRAL

R

C

E

O

M

N

O

T

T

E R

E

T R O L

L E V E

(R2 type)

NEUTRAL

R

C

E

O

M

N

O

T

T

E R

E

T R O L

L E V E

(R3 type)

2.

Set the control lever in the

NEUTRAL position.

The engine does not start unless the control lever is set in the

NEUTRAL position.

NEUTRAL

ENGINE

SWITCH KEY

ON

START

ON

START

3.

Turn the engine 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.

74

STARTING THE ENGINE

COOLING WATER

CHECK HOLE

The starter motor consumes a large amount of current. Do not therefore run it continuously for more than 5 seconds at a time. If the engine does not start within 5 seconds, wait at least 10 seconds before running the starter motor again.

Do not turn the engine switch key to the START position while the engine is running.

’’ prevents the engine from being started unless the control lever is set in the N (neutral) position even though the engine is cranked by the starting motor.

COOLING WATER

INTAKE PORT (each side)

4.

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

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

Check to see if the screen in the cooling water intake port is obstructed and remove foreign materials if necessary. Check the cooling water check hole for clogging. If water still does not flow out, have your outboard motor checked by an authorized

Honda outboard motor dealer. Do not operate the engine until the problem has been corrected.

When the boat is mounted with the two outboard motors, perform the above procedure on the right and left outboard motors respectively.

75

STARTING THE ENGINE

ENGINE OIL PRESSURE

INDICATOR

NORMAL: ON

ABNORMAL: OFF

DIGITAL TACHOMETER

Normal

Abnormal

5.

Check to see if the oil pressure indicator turns ON.

If it does not turn on, stop the engine and perform the following inspections.

1)

2)

Check the oil level (see page 53 ).

If the oil level is normal and the oil pressure indicator light does not turn ON, consult with an authorized Honda outboard motor dealer.

6.

Warm up the engine as follows: for at least 3 minutes.

for at least 5 minutes at approx.

2,000 min (rpm).

Failure to completely warm up the engine will result in poor engine performance.

If the engine is not properly warmed-up before raising the engine speed, the warning buzzer and overheat indicator may activate and the engine speed will be automatically reduced.

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

76

Emergency Starting

STARTING THE ENGINE

6 mm WASHER 6 × 25 mm FLANGE

BOLT

CLAMP

ACG COVER

HOOKS

CLAMPS

ENGINE COVER

FIXING LEVER

(front/rear)

If the starting system does not operate properly for some reasons, the engine can be started using the emergency starter rope in the tool kit.

1.

2.

Turn the engine switch key to the

OFF position.

Raise the front and rear fixing levers, and remove the engine cover.

BREATHER

TUBE

3.

4.

5.

Release the breather tube from the four clamps.

Remove 6 × 25 mm flange bolt and washer, then remove the ACG cover.

Secure the breather tube to the clamp of the silencer case.

CLAMP (on the silencer case)

Take care not to lose the bolt and washer.

77

STARTING THE ENGINE

(H type) NEUTRAL (R2 type)

NEUTRAL

NEUTRAL

SHIFT

LEVER

REMOTE

CONTROL

LEVER

(R1 type)

NEUTRAL

NEUTRAL

(R3 type)

NEUTRAL

NEUTRAL

NEUTRAL

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVER

6.

Set the shift lever or remote control lever is in the NEUTRAL position.

The Neutral Starting System’’ will not work in emergency starting.

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

78

(H type)

‘‘ ’’ MARK

THROTTLE

GRIP

START

7. H type:

Align the ‘‘ ’’ (start mark) on the throttle grip with the projected end of the ‘‘ ’’ mark on the tiller handle.

R1 type:

Leave the fast idle lever in the

START (fully lowered) position.

(R1 type)

STARTING THE ENGINE

EMERGENCY

STARTER ROPE

START

FAST IDLE LEVER

KNOT

AC GENERATOR ROTOR

8.

Set the AC generator rotor so the cutouts are on the right and left sides of the AC generator rotor as shown. Hook the knot at the end of the starter rope (accessory) against a cutout in the AC generator rotor and wind the starter rope one and half turns clockwise along the groove in the AC generator rotor.

79

STARTING THE ENGINE

(H type)

EMERGENCY

STOP SWITCH

(R2, R3 type)

EMERGENCY STOP SWITCH

SPARE EMERGENCY

STOP SWITCH CLIP

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

LANYARD

(R1 type)

EMERGENCY

STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

80

EMERGENCY

STOP SWITCH

LANYARD

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

9.

Insert the clip at the end of the emergency stop switch lanyard into the emergency stop switch.

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

A spare emergency stop switch clip is provided;

R1 type: on the remote

ALL types: control box (see page 31 ).

in the tool bag

(see page 117 ).

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

(H type)

O N

ENGINE SWITCH KEY

(R1 type)

ENGINE

SWITCH KEY

ON

(R2, R3 types)

ON ENGINE

SWITCH KEY

STARTING THE ENGINE

11.

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

If the engine fails to start refer to

Troubleshooting page 144 .

10.

Turn the engine switch key to the

ON position.

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

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

12.

Leave the AC generator cover off and install the engine cover. Lock the engine cover fixing levers.

Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing. Contact your closest authorized Honda outboard motor dealer and have the outboard motor and the electrical system checked.

81

8.

OPERATION

Break-in Procedure

Break-in period: 10 hours

Break-in operation allows the mating surfaces of the moving parts to wear evenly and thus ensures proper performance and longer outboard motor life.

Break-in your new outboard motor as follows.

First 15 minutes:

Run the outboard motor at trolling speed. Use the minimum amount of throttle opening necessary to operate the boat at a safe trolling speed.

Next 45 minutes:

Run the outboard motor up to a maximum of 2,000 to 3,000 min

(rpm) or 10% to 30% throttle opening.

Next 60 minutes:

Run the outboard motor up to maximum of 4,000 to 5,000 min

(rpm) or 50% to 80% throttle opening. Short bursts of full throttle are acceptable but do not operate the motor continuously at full throttle.

Next 8 hours:

Avoid continuous full throttle operation (100% throttle opening).

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

For boats that plane easily, bring the boat up on plane then reduce the throttle opening to the specified break-in settings called out above.

82

Gear Shifting

(H type)

THROTTLE

GRIP

F (FORWARD)

OPERATION

R (REVERSE)

NEUTRAL

N (NEUTRAL)

SLOW

SLOW

The shift lever has 3 positions:

FORWARD, NEUTRAL, and

REVERSE.

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

SHIFT LEVER

REVERSE

FORWARD

1.

Align the pointer on the tiller handle with the SLOW position on the throttle grip to decrease engine speed.

2.

Move the shift lever to engage the desired gear.

Be sure to perform the gearshift operation at a low engine speed.

Shifting the gear at a high engine speed will damage the drive system. Be sure that the gear was shifted securely, then operate the throttle grip to raise the engine speed.

The throttle mechanism is designed to limit throttle opening in

REVERSE and NEUTRAL. Do not turn the throttle grip with force in the

FAST direction. The throttle can be opened to FAST only in FORWARD gear.

83

OPERATION

Gear Shifting

(R1 type)

REMOTE

CONTROL

LEVER

FORWARD

NEUTRAL

FORWARD

NEUTRAL

NEUTRAL

REVERSE

MAXIMUM

OPENING

Pull up

NEUTRAL RELEASE

LEVER

REVERSE

Moving the control lever further from approximately 30° will increase throttle opening and boat speed.

Avoid sharp and abrupt operation of the control lever.

Operate it moderately. Operate the control lever and raise the engine speed after making sure that the gear was shifted securely.

MAXIMUM

OPENING

The control lever will not move unless the neutral release lever is pulled up.

While pulling the neutral release lever, move the control lever approximately 30° toward the

FORWARD or REVERSE position to engage the desired gear.

84

OPERATION

Gear Shifting

(R2 type)

REMOTE CONTROL LEVER

NEUTRAL

FORWARD

FORWARD

P u l l u p

NEUTRAL

RELEASE

LEVER

NEUTRAL

Avoid sharp and abrupt operation of the control lever.

Operate it moderately. Operate the control lever and raise the engine speed after making sure that the gear was shifted securely.

While pulling the neutral release lever, move the control lever approximately 35° toward the

FORWARD or REVERSE position to engage the desired gear.

REMOTE CONTROL

LEVER

REVERSE

Moving the control lever further from approximately 35° will increase throttle opening and boat speed.

The control lever will not move unless the neutral release lever is pulled up.

85

OPERATION

Gear Shifting

(R3 type)

(SINGLE TYPE)

NEUTRAL

(DUAL TYPE)

FORWARD

FORWARD

R E V E R S E

REMOTE

CONTROL

LEVER

Avoid sharp and abrupt operation of the control lever.

Operate it moderately. Operate the control lever and raise the engine speed after making sure that the gear was shifted securely.

Move the control lever(s) approximately 35° toward the

FORWARD or REVERSE position to engage the desired gear.

REMOTE

CONTROL

LEVER

REMOTE CONTROL LEVERS

When the boat is mounted with the two outboard motors, hold the control lever in the center as shown, and operate the right and left levers simultaneously.

86

NEUTRAL

REVERSE

Moving the control lever(s) further from approximately 35° will increase throttle opening and boat speed.

Steering

(H type)

RIGHT TURN LEFT TURN

STEERING FRICTION KNOB

D E C R E A S E

F R I C T I O N

OPERATION

(R type)

Steer the boat in the same manner as an automobile.

Move the tiller handle to the left.

Move the tiller handle to the right.

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

INCREASE

FRICTION

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

Turn the knob clockwise to increase steering friction for holding a steady course.

Turn the knob counterclockwise to decrease friction for easy turning.

87

OPERATION

Cruising (H type)

POWER TRIM/

TILT SWITCH

Press the DN (down) of the power trim/tilt switch and tilt the motor to the lowermost position.

FORWARD

SHIFT

LEVER

LOWERMOST

POSITION

FORWARD

1.

With the shift lever in the

FORWARD position.

88

OPERATION

FAST

THROTTLE FRICTION

ADJUSTER

When cruising at full throttle, note that the engine speed must be in the range BF75D: between 5,000 min (rpm) and 6,000 min (rpm),

BF90D: between 5,300 min

(rpm) and 6,300 min (rpm).

If you feel that the engine speed jumped up when the hull jumped or at ventilation, cruise the boat by returning the throttle to the slow speed side.

‘‘

51 ) for a relation between the propeller and the engine speed.

THROTTLE

GRIP

FAST

2.

Turn the throttle grip in the FAST direction to increase the speed.

For the sake of fuel economy, open the throttle about 80%.

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

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

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

89

OPERATION

Cruising (R type)

(R1 type)

POWER TRIM/TILT

SWITCH

(R2 type)

POWER TRIM/TILT

SWITCH

(R3 type)

(single type)

POWER TRIM/TILT

SWITCH

(dual type)

POWER TRIM/TILT SWITCH

(LEFT) (RIGHT)

1.

Press the DN (down) of the power trim/tilt switch and trim the motor at the lowermost position.

LOWERMOST

POSITION

R3 type:

When the two outboard motors are mounted:

1) Press the DN (down) of the power trim/tilt switch on the control lever side and trim the outboard motors at the lowermost position.

2) With the outboard motors trimmed at the lowermost position, adjust the trim angle of the right and left outboard motors using the switch on the console side separately or using the switch on the control lever simultaneously.

90

OPERATION

(R1 type) (R2 type) (R3 type)

NEUTRAL

FORWARD

REVERSE

NEUTRAL

REVERSE

FORWARD

FORWARD

NEUTRAL

REVERSE

REMOTE

CONTROL

LEVER

REMOTE

CONTROL

LEVER

FORWARD FORWARD

2.

Move the control lever from

NEUTRAL toward FORWARD position.

R1 type:

Moving about 30° engages the gear. Moving the control lever further opens the throttle and increases the engine speed.

FORWARD

R2, R3 types:

Moving about 35° engages the gear.

Moving the control lever further opens the throttle and increase the engine speed.

For the sake of fuel economy, open the throttle about 80%.

When cruising at full throttle, note that the engine speed must be in the range BF75D: between 5,000 min (rpm) and 6,000 min (rpm),

BF90D: between 5,300 min

(rpm) and 6,300 min (rpm).

If you feel that the engine speed jumped up when the hull jumped or at ventilation, cruise the boat by returning the throttle to the slow speed side.

‘‘

51 ) for a relation between the propeller and the engine speed.

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

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

91

OPERATION

Trimming the Motor (H type)

68°

12°

TILT

ANGLE

16°

T R I M A N G L E

− 4°

(VERTICAL LINE)

(when transom angle is 12° )

The BF75D/90D is equipped with the power trim/tilt system which can adjust the motor angle (trim/tilt angle) while cruising and mooring.

The motor angle can also be adjusted while cruising and accelerating to obtain the maximum speed and optimum driveability and fuel economy.

P r e s s U P t o r a i s e b o w .

P r e s s D N t o l o w e r b o w .

POWER TRIM/TILT SWITCH

Press either UP or DN (down) of the power trim/tilt switch and tilt the motor to the best position in compliance with the cruising conditions.

92

(R1 type)

POWER TRIM/TILT SWITCH

Press UP to raise bow.

Press DN to lower bow.

REMOTE

CONTROL

LEVER

(R2 type)

POWER TRIM/TILT SWITCH

Press UP to raise bow.

Press DN to lower bow.

REMOTE

CONTROL

LEVER

The power trim/tilt system operates when the switch is pressed, and it stops when the switch is released.

To trim up slightly, press on UP momentarily but securely.

To trim down slightly, press on DN

(down) in the same manner.

(R3 type)

POWER TRIM/TILT SWITCH

(Single Type)

Press UP to raise bow.

REMOTE

CONTROL

LEVER

Press DN to lower bow.

POWER TRIM/TILT SWITCH

(LEFT) (RIGHT)

(Dual Type)

REMOTE

CONTROL

LEVER

Improper trim angle results in unstable steering condition.

Do not trim excessively while cruising through rough waves, or it may cause an accident.

Excessive trim angle can result in cavitation and racing of the propeller, and trimming up the motor excessively can cause damage to the impeller pump.

Decrease the trim angle on high speed turns to reduce the possibility of propeller ventilation.

Improper motor trim angle can result in an unstable steering condition.

OPERATION

93

OPERATION

MOTOR TRIMMED TOO LOW MOTOR TRIMMED TOO HIGH

MOTOR TRIMMED CORRECTLY

When cruising:

(A) Into a high wind, trim the motor down slightly to lever the bow and

(B) improve boat stability.

With a tail wind, trim the motor up slightly to raise the bow and improve

(C) boat stability.

Through rough waves, do not trim the motor too low or too high to avoid an unstable steering condition.

94

Trim Meter

(equipped type or optional equipment)

The trim meter indicates the trim angle of the motor. Refer to the trim meter, and press the UP or DN

(down) portion of the power trim/tilt switch to adjust the motor trim angle to achieve boat performance and stability.

The illustration represents R1 type.

Perform the same procedure for the other types.

BOW TOO LOW DUE TO

1. LOAD IN THE FRONT

2. MOTOR TRIMMED TOO LOW

Digital Tachometer

When the boat is mounted with the two outboard motors, adjust with the switch on the control lever side.

Adjustment with the switch on the console side will impair the balance between the right and left outboard motors, which adversely affects operationability and stability of the outboard motors.

With the motor trimmed low the trim meter will read as shown. To raise the bow increase the motor trim angle by pressing the UP portion of the power trim/tilt switch.

OPERATION

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. MOTOR TRIMMED TOO HIGH

Digital Tachometer

With the motor trimmed high the trim meter will read as shown. To lower the bow decrease the motor trim angle by pressing the DN

(down) portion of the power trim/tilt switch.

95

OPERATION

Tilting the Motor

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

Please tilt up simultaneously, when you mount the dual type outboard motor.

1.

2.

Move the remote control lever to the NEUTRAL position and stop the engine.

Press the UP of the power trim/tilt switch and tilt the motor to the best position in compliance.

(H type)

(R1 type)

POWER TRIM/TILT SWITCH

(R3 type)

(single type)

POWER TRIM/TILT SWITCH

(R2 type)

POWER TRIM/TILT SWITCH

(dual type)

POWER TRIM/TILT SWITCH

(LEFT) (RIGHT)

96

POWER TRIM/TILT

SWITCH

Moorage

F R E E

L O C K

TILT LOCK LEVER

Tilt up the outboard motor using the tilt lock lever when mooring the boat.

Shift the control lever into the

NEUTRAL position and stop the engine before tilting up the outboard motor.

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

TILT LOCK LEVER

1.

2.

3.

4.

Raise the motor as far as it goes using the power trim/tilt switch.

Move the tilt lock lever to the

LOCK position and lower the outboard motor until the lock lever contacts the stern bracket.

Press the DN (down) of the power trim/tilt switch and fully shorten the trim rods.

To tilt down, raise the outboard motor as far as it goes using the power trim/tilt switch, move the tilt lock lever to the FREE position.

OPERATION

TRIM RODS

97

OPERATION

(R3 type) (DUAL TYPE)

POWER TRIM/TILT SWITCH

(LEFT) (RIGHT)

Power Tilt Switch

POWER TILT SWITCH

After tilting down the outboard motors, adjust the trim angle of the right and left outboard motors.

When you are away from the power trim/tilt switch on the control lever side, you can operate the power tilt switch on the outboard motor side.

The switch operation is the same as that of the power trim/tilt switch on the control lever side.

Do not operate this power tilt switch on the outboard motor while sailing.

98

Manual Relief Valve

MANUAL RELIEF VALVE

P O

( T o

W E o f i x )

R

(

M

T

A o

N r e

U l e

A a

L s e )

When power trim/tilt system does not operate because of dead battery or faulty power trim/tilt motor, the outboard motor can be manually tilted up or down by operating the manual relief valve.

To tilt the outboard motor manually, turn the manual relief valve under the stern bracket 1 or 2 turns counterclockwise using a screwdriver.

Do not loosen the manual relief valve more than two turns, or the outboard motor cannot be tilted up when the manual relief valve is retightened.

After tilting up/down manually, close the manual relief valve to lock the motor in the position.

Check that no person is under the outboard motor before carrying out this operation because if the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down.

The manual relief valve must be tightened securely before operating the motor or the motor could tilt when operating in reverse.

OPERATION

99

OPERATION

Trim Tab Adjustment

GEAR CASE

GROMMET

GEAR CASE

GROMMET

RIGHT

LEFT

The trim tab is provided to adjust for

‘‘ torque steer which is a reaction of the propeller rotation or propeller torque. If during a high speed turn an unequal amount of effort is required to turn the boat right or left, adjust the trim tab so that an equal amount of effort is required.

Distribute the load evenly in the boat and run the boat in a straight course at full throttle. Slightly turn the steering wheel for both right and left turns to determine the amount of effort required.

100

TRIM TAB

TIGHTENING

BOLT

Remove the gear case grommet and loosen the tightening bolt to adjust the trim tab. After adjustment, reinstall the grommet securely.

If less effort is required to make left turns:

Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the left. Tighten the bolt securely.

TRIM TAB

TIGHTENING

BOLT

If less effort is required to make right turns:

Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the right. Tighten the bolt securely.

Make small adjustments at a time and retest. Incorrect trim tab adjustment can cause adverse steering.

OPERATION

Motor Protection System

〈 Engine Oil Pressure, Overheat,

Water Contamination, PGM-FI and ACG Warning Systems 〉

OIL PRESSURE

INDICATOR

(GREEN)

ACG

INDICATOR

OVERHEAT

INDICATOR

(RED)

OIL PRESSURE

(GREEN)

ACG INDICATOR

PGM-FI

INDICATOR

INDICATOR

OVERHEAT

(RED)

BUZZER

BUZZER OIL PRESSURE

(GREEN)

(R1 type)

(R type)

PGM-FI INDICATOR

DIGITAL TACHOMETER (R type)

OIL PRESSURE

INDICATOR

ACG INDICATOR

(internal buzzer)

(H type)

(R2, R3 types)

OVERHEAT

(RED)

OVERHEAT INDICATOR

PGM-FI INDICATOR

101

OPERATION

If the engine oil pressure drops and/ or the engine overheats, either or both warning systems could be activated.

When activated the engine speed will decrease gradually and the oil pressure indicator will turn OFF and the overheat indicator will turn ON.

A continuous buzzer will sound on all type.

The engine speed can not be increased with a larger throttle opening until the malfunction is corrected.

When the malfunction is corrected the engine speed will increase gradually.

If the engine overheats, the engine will stop in 20 seconds after the engine protection system will limit engine speed.

Each warning system of PGM-FI,

ACG, oil pressure, overheat, and water contamination is activated as described in the following table.

102

Symptom

At starting

During operation

Low oil pressure

Overheat

ACG warning

PGM-FI warning

Water contamination

System

Oil pressure

(Green)

ON (2 sec)

ON

OFF

ON

ON

ON *

ON

INDICATOR LIGHTS

Overheat

(Red)

ACG

(Red)

ON (2 sec) ON

OFF

OFF

ON

OFF

OFF *

OFF

OFF

OFF

OFF

ON

OFF

OFF

PGM-FI

(Red)

ON (2 sec)

OFF

OFF

OFF

OFF

ON

OFF

OPERATION

BUZZER

CORRESPONDING

SYSTEM

With the engine key turned on: ON (2 times)

OFF

ON (continuously)

ON (continuously) alternating ON and OFF

(at long intervals) alternating ON and OFF

(at long intervals) alternating ON and OFF

(at short intervals)

Some indicator and/or buzzer will be activated at the same time due to the occurrence of a malfunction.

* : Occasionally may blink due to the occurrence of a malfunction.

103

OPERATION

System

Symptom

At starting

During operation

Low oil pressure

Overheat

ACG warning

PGM-FI warning

Water contamination

Oil pressure

Indicator (1)

ON (2 sec)

ON

OFF

ON

ON

ON *

ON

Overheat

Indicator (1)

ON (2 sec)

OFF

OFF

ON

OFF

OFF *

OFF

INDICATOR

ACG

Indicator (1)

ON (2 sec)

OFF

OFF

OFF

ON

OFF

OFF

PGM-FI

Indicator (1)

ON (2 sec)

OFF

OFF

OFF

OFF

ON

OFF

Water Separator

Indicator (2)

ON (2 sec)

OFF

OFF

OFF

OFF

OFF

ON

BUZZER

CORRESPONDING

SYSTEM

With the engine key turned on: ON (2 times)

OFF

ON (continuously)

ON (continuously) alternating ON and OFF

(at long intervals) alternating ON and OFF

(at long intervals) alternating ON and OFF

(at short intervals)

Some indicator and/or buzzer will be activated at the same time due to the occurrence of a malfunction.

* : Occasionally may blink due to the occurrence of a malfunction.

(1) The digital tachometer includes this function.

(2) The digital speedometer includes this function.

104

OPERATION

When the oil pressure warning system is activated:

1.

2.

Stop the engine immediately and check the engine oil level (see page 53 ).

If the oil is up to the recommended level, restart the engine. If the oil pressure warning system stops after 30 seconds, the system is normal.

COOLING WATER CHECK HOLE

If the throttle was closed suddenly after cruising at full throttle, the engine speed may drop below the specified idle speed. This could cause the oil pressure warning system to activate momentarily.

3.

If the oil pressure warning system stays activated after 30 seconds, return to the closest boat landing and contact your closest authorized

Honda outboard motor dealer.

When the overheat warning system is activated:

1.

2.

Return the shift lever or remote control lever to the N (neutral) position immediately. Check to see if water is flowing out of the cooling water check hole.

If water is flowing out of the cooling water check hole, continue idling for 30 seconds. If the overheat warning system stops after 30 seconds the system is normal.

If the motor is turned off after running at full throttle, the engine temperature may rise above normal.

If the motor is restarted, shortly after being turned off, the overheat warning system could be activated momentarily.

105

OPERATION

COOLING WATER INTAKE PORT

(each side)

3.

If the overheat warning system stays activated, stop the engine.

Tilt up the motor and check the water intakes for obstructions. If there are no obstructions at the water intakes, return to the closest boat landing and contact your closest authorized Honda outboard motor dealer.

106

When the PGM-FI activated:

1.

Consult with an authorized Honda outboard motor dealer.

When the ACG warning system is activated.

1.

Check the battery (see page 134 ).

If the battery is OK, consult with an authorized Honda outboard motor dealer.

WATER

SEPARATOR

When the water separator buzzer sounds:

1.

Check the water separator for water contamination. If water is accumulated, clean them (see page

127 ).

〈 Anode 〉

ANODE (each side)

OPERATION

〈 Over-rev Limiter 〉

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

When the over-rev limiter is activated:

1.

2.

Reduce the throttle opening immediately and check the trim angle.

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

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

ANODE

(stern bracket)

The anode is a sacrificial material which helps to protect the outboard motor from corrosion.

Painting or coating the anode will lead to rust and corrosion damage to the outboard motor.

There are also 2 small sacrificial anodes in the water passages of the engine block.

107

OPERATION

Shallow Water Operation

Excessive trim/tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump and overheat the engine.

When operating in shallow water, tilt the motor up to prevent the propeller and gear case from hitting the bottom

(see page 96 ). With the motor tilted up, operate the motor at low speed.

Monitor the cooling water check hole for water discharge. Be sure that the motor is not tilted so high that the water intakes are out of the water.

108

Emergency Engine Stop

(H type)

EMERGENCY

STOP SWITCH

(R1 type)

EMERGENCY

STOP SWITCH

9.

STOPPING THE ENGINE

Pull the lanyard of the emergency stop switch and remove the emergency stop switch clip from the switch; this will stop the engine.

It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be sure that the emergency stop switch is operating properly.

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

EMERGENCY

STOP SWITCH

CLIP

EMERGENCY STOP

SWITCH LANYARD

(R2, R3 types)

EMERGENCY STOP

SWITCH CLIP

EMERGENCY

STOP SWITCH

EMERGENCY STOP SWITCH

LANYARD

109

STOPPING THE ENGINE

Normal Engine Stop

(H type)

THROTTLE

GRIP

SHIFT

LEVER

NEUTRAL

SLOW

SLOW

1.

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

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

NEUTRAL

ENGINE

SWITCH KEY

OFF

2.

Turn the engine switch key to the

OFF position to stop the engine.

In the event that the engine does not stop when the engine switch is turned to OFF, push the emergency stop switch to stop the engine.

3.

Remove the engine switch key and store it.

110

(R type)

NEUTRAL

NEUTRAL

NEUTRAL

REMOTE

CONTROL

LEVER (R1 type)

REMOTE

CONTROL

LEVER

(R2 type)

NEUTRAL

1.

Move the control lever to the

NEUTRAL position.

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

REMOTE

CONTROL

LEVER

(R3 type)

NEUTRAL

STOPPING THE ENGINE

ENGINE

SWITCH KEY

O F F

(R1 type)

EMERGENCY

STOP SWITCH

O F F

NEUTRAL

ENGINE

SWITCH KEY

(R2, R3 types)

2.

Turn the engine switch key to the

OFF position to stop the engine.

111

STOPPING THE ENGINE

In the event that the engine does not stop when the engine switch is turned to OFF, push the emergency stop switch to stop the engine.

3.

Remove the engine switch key and store it.

112

Fuel Line Disconnection

Before transporting the motor, disconnect and remove the fuel line.

Transporting

ENGINE HANGERS

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

Be careful not to spill fuel.

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

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

When transporting the outboard motor on a vehicle, perform the following.

1.

Remove the engine cover.

10.

TRANSPORTING

ENGINE

HANGERS

HOIST

HOOKS

2.

Set the hoist hooks against the two engine hangers and hang the outboard motor to remove it from the boat.

113

TRANSPORTING

OUTBOARD MOTOR STAND

3.

4.

Secure the outboard motor on a outboard motor stand with the mounting bolts and nuts.

Remove the hoist hook and reinstall the engine cover.

Trailering

(H type)

STEERING FRICTION

ADJUSTING KNOB

When trailering or transporting the boat with the motor attached, it is recommended that the motor remain in normal running position with the steering friction adjusting knob tightened securely.

(R type)

When trailering or transporting the boat with the motor attached, it is recommended that the motor remain in normal running position.

Do not trailer or transport the boat with the motor in the tilted position.

The boat or motor could be severely damaged if the motor drops.

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

114

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

FLUSH PORT

CONNECTOR

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover, such as the O2 sensor. If water or corrosion inhibitor penetrates these components, they may be damaged. Before applying a corrosion inhibitor, cover the O2 sensor (and belt, if applicable) with a protective material to prevent damage.

Shut off the engine before performing the cleaning and flushing.

1.

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

FLUSH PORT

CONNECTOR

2.

3.

Disconnect the flush port connector.

Screw the flush port connector onto the garden hose.

11.

CLEANING AND FLUSHING

4.

5.

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

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

When using the water hose joint:

WATER HOSE JOINT

(commercially available)

FLUSH PORT

CONNECTOR

WATER HOSE

115

12.

MAINTENANCE

Periodic maintenance and adjustment are important to keep the motor in the best operating condition. Service and inspect according to the

MAINTENANCE SCHEDULE.

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

Never run the engine in an enclosed or confined area.

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

Be sure to reinstall the engine cover, if it was removed, before starting the engine. Lock the engine cover fixing lever securely (see page 52 ).

If the engine must be run, make sure there is water at least 100 mm (4 in) above the anticavitation plate, otherwise the water pump may not receive sufficient cooling water, and the engine will overheat.

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

116

MAINTENANCE

Tool Kit and Emergency Parts

The following tools and emergency starter rope, spare emergency stop switch clip are supplied with the outboard motor for maintenance, adjustment, and emergency repairs.

EMERGENCY

STARTER ROPE

10 × 14 mm WRENCH SPARK PLUG WRENCH

8 × 12 mm WRENCH

OIL CHECK

SCREWDRIVER

PHILLIPS/FLAT

SCREWDRIVER

SCREWDRIVER

HANDLE

18 × 19 mm BOX WRENCH

10 mm BOX WRENCH

PLIERS

FUSE PULLER

SPARE EMERGENCY

STOP SWITCH CLIP

TOOL BAG

117

MAINTENANCE

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

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

ITEM

Engine oil

Gear case oil

Engine oil filter

Throttle linkage

Idling speed

Valve clearance

Spark plug

Propeller and cotter pin

Anode

Lubrication

Water separator

Check level

Change

Change

Replace

Check-adjust

Check-adjust

Check-adjust

Check

Clean

Replace

Check

Check

Grease

Check

Each use After use

First month or

20 hrs.

Every

6 months or

100 hrs.

(2) ○

(2)

Every year or

200 hrs.

○ (2)

(2)

(2)

(2)

(2)

○ (2)

(2)

Every

2 years or

400 hrs.

Refer to page

53

120

122

○ (1) ○ (1)

○ 122

57

62

125, 126

60

(1)

(2)

(3)

Lubricate more frequently when used in salt water.

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

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

118

ITEM

Fuel filter

(Low pressure side)

Fuel filter

(High pressure side)

Fuel tank and tank filter

Thermostat

Fuel tube

Battery and cable connection

Bolts and Nuts

Breather tube

Cooling water passages

Water pump

Emergency stop switch

MAINTENANCE

REGULAR SERVICE PERIOD

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

(3)

Check

Replace

Check

Replace

Clean

Check

Check

Replace

Check level-tightness

Check-tightness

Check

Clean

Check

Check

Each use After use

First month or

20 hrs.

Every

6 months or

100 hrs.

Every year or

200 hrs.

○ (2)

Every

2 years or

400 hrs.

Refer to page

130

131

○ (2)

(2)

132

62 ○

○ (4)

Every 2 years (if necessary) (2)

○ (2) ○ (2)

○ (2)

○ (2)

60, 134

(1)

(2)

(3)

(4)

Lubricate more frequently when used in salt water.

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

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

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

119

MAINTENANCE

Engine Oil

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

Oil change interval:

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

Oil capacity:

4.2

(4.4 US qt , 3.7 Imp qt)

…when oil filter is not replaced

4.4

(4.6 US qt , 3.9 Imp qt)

…when oil filter is replaced

Recommended Oil:

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

SG, SH or SJ.

〈 Engine Oil Replacement 〉

OIL FILLER CAP

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

1.

Position the outboard motor vertically, and remove the engine cover. Remove the oil filler cap

(see page 54 ).

DRAIN BOLT

SEALING WASHER

GUIDE

2.

3.

Place a suitable container under the guide.

Remove the engine oil drain bolt and sealing washer using the 12 mm wrench and drain the engine oil.

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

120

6.

7.

Reinstall the oil filler cap securely.

Do not overtighten (see page 54 ).

Install and lock the engine cover securely.

UPPER

LEVEL

MARK

LOWER

LEVEL

MARK

OIL LEVEL DIPSTICK

4.

5.

Refill to the upper level mark on the oil level dipstick with the recommended oil.

Install the dipstick securely.

Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash or pour it on the ground.

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

MAINTENANCE

121

MAINTENANCE

Spark Plugs

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

Check interval:

Every 200 hours or 12 months.

Replace interval:

Every 400 hours or 2 years

Recommended spark plug:

IZFR6K-11E (NGK)

The spark plug becomes very hot during operation and will remain hot for a while after stopping the engine. Allow the engine to cool before servicing the spark plug.

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

This outboard motor uses spark plugs that have an iridium coated center electrode. Be sure to observe the following when servicing the spark plugs.

Do not clean the spark plugs. If an electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one.

The cleaning of the iridium spark plugs consult with an authorized

Honda outboard motor dealer, unless the owner has the proper tools and is mechanically proficient.

Use only a ‘‘wire-type feeler gauge’’ to check the spark plug gap if necessary. To prevent damaging the iridium coating of the center electrode, never use a

‘‘leaf-type feeler gauge.’’

Do not adjust the spark plug gap.

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

122

〈 Inspection and Replacement 〉

1.

2.

Disconnect the battery negative

( ) terminal.

Unlock and remove the engine cover (see page 52 ).

6 × 20 mm

FLANGE SH BOLT

MAINTENANCE

CONNECTOR

LOCK TAB

IGNITION

COIL

PLUG MAINTENANCE COVER

3.

Remove the 6 × 20 mm flange

SH bolt and remove the plug maintenance cover.

6 × 25 mm

FLANGE BOLT

4.

Remove the 6 × 25 mm flange bolt.

Disconnect the connector by pushing the lock tab and remove the ignition coil.

123

MAINTENANCE

BOX WRENCH

PLUG WRENCH

5.

6.

Remove the spark plug using the plug wrench, box wrench and the

Phillips /flat-tip screwdrivers

(accessories).

Check the electrodes for wear, the insulator for cracks and the sealing washer for damage. Replace the spark plug if necessary.

SEALING WASHER

If installing new spark plugs, tighten

1/2 turn after the spark plugs seat to compress the washers.

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

INSULATOR

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

7.

Measure the plug gaps with a wiretype feeler gauge.

8.

9.

(0.039 0.051 in). If the gap is out of the specification, replace the plug with a new one. Never try to readjust the gap.

Thread the plugs in by the plug wrench to prevent cross threading.

After the spark plugs are seated, tighten with a spark plug wrench and box wrench to compress the washers.

10.

11.

12.

13.

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

Install the ignition coil. Reinstall the bolt.

Repeat this procedure for the other three spark plugs.

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

124

Lubrication

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

Lubrication interval:

20 hours or a month after the date of purchase for initial lubrication, then every 100 hours or 6 months.

Apply anticorrosion oil to pivot surfaces where grease cannot penetrate.

Lubricate more frequently when used in salt water.

THROTTLE ARM/

LINK/PIVOT/PLATE THROTTLE ROD/LINK

MAINTENANCE

TILLER HANDLE

(H type)

TILT BRACKET

TILT SHAFT

PROPELLER SHAFT SWIVEL CASE THRUST RECEIVER

125

MAINTENANCE

SHIFT LINK BRACKET/

SHIFT PIVOT/SHIFT ARM/

LINK PIN/PIVOT PLATE/

SLIDE PIVOT/

CLICK SPRING ROLLER

TILT LOCK LEVER

(each side) TILT SHAFT THREAD

UPPER CYLINDER

PIN/BUSHING

MOUNT FRAME

SWIVEL SHAFT

LOWER CYLINDER

BUSHING/COLLAR

126

MAINTENANCE

Water Separator

WATER SEPARATOR

Water separator is located near by the engine cover fixing lever of the boat side. Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with an authorized Honda outboard motor dealer for clean.

〈 Cleaning 〉

FUEL TUBES SCREWS (3)

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT

OF REACH OF CHILDREN.

Always work in a wellventilated area.

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

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

SUSPENSION STRAP

WATER SEPARATOR

BRACKET

WATER

SEPARATOR

1.

2.

Remove the engine cover (see page 52 ).

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

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

127

MAINTENANCE

HARNESS

CLIP

WATER LEVEL SENSOR

2P CONNECTOR

CLIP C

CUP

O-RING

Assemble so the flat part on the back of the suspension is parallel to the water separator joint as shown below.

Assemble so the flat part of the suspension and the water separator joint are parallel to each other.

3.

4.

5.

Open the harness clip and remove the harness from the clip C, then disconnect the water level sensor

2P connector.

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

Disconnect the fuel tubes from the water separator.

WATER

SEPARATOR

CUP

SUSPENSION

STRAP

6.

7.

8.

Remove the three screws and separate the water separator cup from the body.

Thoroughly clean the water separator cup.

Reassemble the water separator body and the cup.

TIGHTENING TORQUE:

3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)

WATER

SEPARATOR

FLAT PART ON BACK

OF SUSPENSION

JOINT

128

POSITIONING

BAND

HARNESS

CLIP

WATER LEVEL

SENSOR 2P

CONNECTOR

10.

11.

Reinstall the water separator in the reverse order of removal.

Squeeze and release the priming bulb to fill the vapor separator, and check for leaks.

CLIP C

POSITIONING

BAND

9.

Connect the water level sensor 2P connector. Install the harness to the clip C and harness clip.

Align the positioning bands on the harness with the end of the clip C and harness clip as shown above.

If the buzzer sounds, water or sediment accumulation is found to be caused by excessive water or sediment accumulated in the water separator cup, inspect the fuel tank.

Clean the fuel tank if necessary.

MAINTENANCE

129

MAINTENANCE

Fuel Filter

FUEL FILTER

(inside strainer cup)

The fuel filter (inside the strainer cup) is located between the fuel pump and the water separator.

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

Inspection interval:

Every 100 operating hours or 6 months

Replacement interval:

Every 400 operating hours or 2 years

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT

OF REACH OF CHILDREN.

Always work in a wellventilated area.

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

Be careful not to spill fuel when replacing the filter.

Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

130

〈 Inspection 〉 〈 Replacement 〉

FUEL TUBES

MAINTENANCE

FUEL FILTER

(inside strainer cup)

FUEL INTAKE

SIDE JOINT

EDGE AT

THE BASE

OF JOINT

FUEL FILTER

(inside strainer cup)

1.

2.

Remove the engine cover (see page 52 ).

Looking through the translucent strainer cup, check the fuel filter for water accumulation and clogging.

If necessary, replace the fuel filter with a new one.

FUEL FILTER BRACKET

SUSPENSION STRAP

1.

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

Before removing the filter, pinch the fuel tubes on each side of filter using tube clips to prevent fuel leakage.

2.

Disconnect the fuel tubes from the fuel filter.

ALIGNMENT

MARK ON THE

SUSPENSION

SUSPENSION STRAP

3.

Install a new fuel filter in the reverse order of removal.

Assemble the fuel filter with the strainer cup by aligning the edge at the base of the fuel intake side joint of the fuel filter with the alignment mark on the suspension as shown above.

131

MAINTENANCE

4.

Prime the engine using the priming bulb (see page 65 ). Check for fuel leaks. Repair any fuel leaks if necessary.

Fuel Tank and Tank Filter

(equipped type)

FUEL LINE

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

Cleaning interval:

Every year or after every 200 hours of outboard motor operation.

〈 Fuel Tank Cleaning 〉

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT

OF REACH OF CHILDREN.

Always work in a wellventilated area.

Be sure that any fuel drained from the fuel tank is stored in a safe container.

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

132

1.

2.

Disconnect the fuel line from fuel tank.

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

Drain and dispose of the gasoline properly.

〈 Tank Filter Cleaning 〉

FUEL TANK CONNECTOR

FILTER

1.

2.

3.

Turn the fuel tank connector counterclockwise and remove the tank filter.

Clean the filter with nonflammable solvent. Replace the tank filter if necessary.

After cleaning, reinstall the tank filter and tank connector securely.

MAINTENANCE

EMISSION CONTROL SYSTEM

The combustion process produces carbon monoxide and hydrocarbons.

Control of hydrocarbons is very important because under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide dose not react in the same way, but it is toxic.

Problems that May Affect Outboard

Motor Emissions

If you are aware of any of the following symptoms, have the outboard motor inspected and repaired by your authorized Honda

Dealer:

1.

Hard starting or stalling after

2.

3.

4.

starting

Rough idle

Misfiring or backfiring during acceleration

Poor performance (driveability) and poor fuel economy

133

MAINTENANCE

Battery

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

Batteries produce explosive gases: If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid. Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.

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

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

POISON: Electrolyte is poison.

ANTIDOTE:

− External: Flush thoroughly with water.

− Internal: Drink large quantities of water or milk.

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

KEEP OUT OF REACH OF

CHILDREN.

UPPER LEVEL

BATTERY

CAP

LOWER LEVEL

〈 Battery Fluid Level 〉

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

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

134

MAINTENANCE

1.

Battery Cleaning 〉

Disconnect the battery cable at the

2.

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

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

NEGATIVE ( )

TERMINAL

POSITIVE ( )

TERMINAL

RED

BLACK

3.

Connect the battery positive ( ) cable to the battery positive ( ) terminal, then the battery negative

− and nuts securely. Coat the battery terminals with grease.

When disconnecting the battery cable, be sure to disconnect at the battery negative ( − ) terminal first. To connect, connect at the positive ( + ) terminal first, then at the negative ( − ) terminal. Never dis/connect the battery cable in the reverse order, or it causes a short circuit when a tool contacts the terminals.

135

MAINTENANCE

Fuse FUSE PULLER

(supplied in the tool bag)

BLOWN FUSE

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

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

Disconnect the battery cable at the battery negative ( − ) terminal before replacing the fuse.

Failure to do so may cause a short circuit.

136

LOCK TABS

ELECTRICAL PART COVER

FUSE CASE LID SPARE FUSES

(10A, 15A, 30A)

FUSES

(10A, 15A, 30A)

If the fuse is blown, check the cause, then replace the fuse with a spare fuse of the same rated capacity. Unless the cause is found, the fuse may blow again.

1.

2.

3.

4.

〈 Replacement 〉

5.

Stop the engine.

Remove the engine cover.

Remove the electrical part cover.

Remove the fuse case lid and pull the old fuse out of the clip with the fuse puller supplied in the tool bag.

Push a new fuse into the clips.

DESIGNATED FUSE:

10A, 15A, 30A

ACG Fuse

‘‘ ’’

FUSE CASE

LID

SPARE FUSE (70A)

ACG FUSE (70A)

Disconnect the battery cable at the battery terminal before checking or replacing the ACG fuse.

MAINTENANCE

〈 Replacement 〉

A spare fuse is located on the reverse side of the fuse case lid and tightened with two 3 mm screws.

When the new fuse in set as a spare fuse on the reverse side of the fuse

1.

2.

3.

case lid, set the fuse so that you can see the 70A mark on it.

4.

5.

6.

Stop the engine.

Remove the engine cover.

Remove the electrical part cover.

Remove the fuse case lid.

Remove the old fuse by removing two 5 mm screws.

‘‘ ’’

7.

8.

mark downward.

After finishing replacement, install the fuse case lid with its hook toward the engine side.

Be sure to check the fuse case lid is securely locked.

DESIGNATED FUSE:

70A

137

MAINTENANCE

Propeller PROPELLER (optional equipment)

COTTER PIN

CASTLE NUT

THRUST WASHER

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

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

The propeller is thin and sharp. To protect your hands, wear the heavy gloves during replacement.

18.5 mm

WASHER

COTTER PIN

Replacement

1.

Remove the cotter pin then remove the 18 mm castle nut, washer, propeller and thrust washer.

2.

3.

Install the new propeller in the reverse sequence to removal.

Tighten the castle nut with your hand first until the propeller has no play. Then, tighten the castle nut again with a tool until the groove in the castle nut aligns with the cotter pin hole. (Note that this tool is not included in the tools that come together with the outboard

138 motor.)

CASTLE NUT

TIGHTENING TORQUE:

1 N·m (0.1 kgf·m, 0.74 lbf·ft)

UPPER LIMIT OF TORQUE:

44 N·m (4.5 kgf·m, 33 lbf·ft)

4.

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

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

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

Submerged Motor

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

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

1.

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

If the motor 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 motor until it has been repaired.

2.

Drain the vapor separator as described on page 141 .

3.

4.

5.

6.

7.

Change the engine oil (see page

120 ).

Remove the spark plugs (see page

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

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

Reinstall the spark plugs.

Install the engine cover and lock the fixing lever securely (see page

52 ).

Attempt to start the engine.

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

MAINTENANCE

8.

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

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

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

139

13.

STORAGE

For longer service life of the outboard motor, have your outboard motor serviced by an authorized

Honda outboard motor dealer before storage. However, the following procedures can be performed by you, the owner, with a minimum of tools.

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

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

Using contaminated gasoline can seriously damage the engine (fuel system clogged, valve stuck).

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

To avoid this please strictly follow these recommendations:

Only use specified gasoline (see page 55 ).

Use fresh and clean gasoline.

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

140

If long storage (more than 30 days) is foreseen, drain fuel tank and vapor separator.

STORAGE

Vapor Separator Draining

INTAKE MANIFOLD DRAIN TUBE

Gasoline is extremely flammable, and gasoline vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT

OF REACH OF CHILDREN.

Be careful not to spill fuel.

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

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

DRAIN SCREW VAPOR SEPARATOR

1.

2.

3.

4.

5.

Remove the engine cover.

Release the drain tube from the projection of the intake manifold and bring the end of the drain tube out of the under cover.

Loosen the vapor separator drain screw.

Tilt up the outboard motor.

When the gasoline starts to flow out of the drain tube, tilt up the outboard motor and hold it in the position until the gasoline stops flowing. After draining the gasoline completely, return the

6.

outboard motor to the horizontal position.

Catch the draining gasoline in a suitable container.

After draining, tighten the drain screw and secure the drain tube to the projection of the intake manifold.

141

STORAGE

Battery Storage

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

Batteries produce explosive gases: If ignited, an explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid. Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.

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

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

POISON: Electrolyte is poison.

ANTIDOTE

− External: Flush thoroughly with water.

− Internal: Drink large quantities of water or milk.

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

KEEP OUT OF REACH OF

CHILDREN.

BLACK

RED

1.

2.

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

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

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

142

STORAGE

Outboard Motor Position

(Port side turned down as shown.)

3.

4.

5.

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

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

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

OUTBOARD MOTOR STAND

Transport and store the motor either vertically, as shown above. Attach the stern bracket to stand and secure the motor with bolts and nuts. Store the outboard motor in a wellventilated area free from direct sunlight and humidity.

Do not place the outboard motor on its side during a prolonged period of storage. If you are obliged to place the outboard motor on its side, drain the engine oil, protect the outboard motor by wrapping it with the urethane material or the blanket as shown.

143

14.

TROUBLESHOOTING

WARNING SYSTEM COMES ON

SYMPTOM POSSIBLE CAUSE

Overheat warning system comes on:

Overheat indicator comes on.

Overheat warning buzzer sounds.

Engine speed decreases and stops at last.

Engine speed cannot be increased by opening the throttle.

Engine will stop in 20 seconds after engine speed is limited.

Cooling water intake port clogged.

Spark plugs have improper heat range.

Faulty water pump.

Thermostat clogged.

Faulty thermostat.

Cooling water passage clogged.

Exhaust gas invades cooling system.

Oil pressure warning system comes on:

Oil pressure indicator does not come on.

Oil pressure warning buzzer sounds.

Engine speed decreases.

Engine speed cannot be increased by opening the throttle.

Shortage of engine oil

Improper engine oil is used.

REMEDY

Clean the cooling water intake port.

Replace the spark plugs (see page 122).

Consult with an authorized Honda outboard motor dealer.

Add engine oil to the specified level (see page 53).

Change the engine oil

(see page 120).

144

SYMPTOM

Water separator warning system comes on:

Water separator warning buzzer sounds.

PGM-FI warning system comes on:

PGM-FI indicator comes on.

PGM-FI warning buzzer sounds intermittently.

ACG warning system comes on:

ACG indicator comes on.

ACG warning buzzer sounds intermittently.

POSSIBLE CAUSE

Water is accumulated in the water separator.

PGM-FI warning system is faulty.

Battery voltage is too high or low.

Faulty ACG.

TROUBLESHOOTING

REMEDY

Clean the water separator (see page 127).

Check the fuel tank and fuel line for water accumulation. If the buzzer sounds again, consult with an authorized Honda outboard motor dealer.

Consult with an authorized

Honda outboard motor dealer.

Check the battery (see page 134).

Consult with an authorized

Honda outboard motor dealer.

145

15.

SPECIFICATIONS

MODEL

Description

Code

Type

Overall length

Overall width

Overall height

Transom height

(when Transom angle is 12° )

Dry weight *

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Remote control steering system

Starter system

Ignition system

Lubrication system

BF75D

BBAJ

LHT

904 mm

(35.6 in)

646 mm

(25.4 in)

1,566 mm

(61.7 in)

537 mm

(21.1 in)

LRT XRT

746 mm

(29.4 in)

449 mm

(17.7 in)

1,693 mm

(66.7 in)

664 mm

(26.1 in)

171 kg

(377 lbs)

165 kg

(364 lbs)

55.2 kW (75 PS)

5,000 − 6,000 min (rpm)

171 kg

(377 lbs)

4 stroke OHC in-line 4-cylinder

1,496 cm (91.3 cu-in)

1.0

− 1.3 mm (0.039

− 0.051 in)

Motor-mounted, remote control

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Oil capacity

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear shift

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine:

Gear case:

API standard SG, SH, SJ SAE 10W-30

API standard GL-4 SAE 90 outboard

Engine: motor gear oil

Without oil filter replacement:

4.2

(4.4 US qt , 3.7 Imp qt)

With oil filter replacement:

Gear case:

4.4

(4.6 US qt , 3.9 Imp qt)

0.95

(1.00 US qt , 0.84 Imp qt)

12 V − 35 A

Water cooling with thermostat

Water exhaust

IZFR6K-11E (NGK)

Electric powered mechanical

Automotive unleaded gasoline

(91 research octane, 86 pump octane, or higher)

Dog type: Forward − Neutral − Reverse

30° right and left

− 4° to 16°

68°

(when Transom angle is 12°)

(when Transom angle is 12°)

8°, 12°, 16°, 20°, 24°

* Without battery cable, with propeller

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

146

SPECIFICATIONS

MODEL

Description

Code

Type

Overall length

Overall width

Overall height

Transom height

(when Transom angle is 12° )

Dry weight *

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Remote control steering system

Starter system

Ignition system

Lubrication system

BF90D

BBCJ

LHT

904 mm

(35.6 in)

646 mm

(25.4 in)

1,566 mm

(61.7 in)

537 mm

(21.1 in)

LRT XRT

746 mm

(29.4 in)

449 mm

(17.7 in)

1,693 mm

(66.7 in)

664 mm

(26.1 in)

172 kg

(379 lbs)

166 kg

(366 lbs)

66.2 kW (90 PS)

5,300 − 6,300 min (rpm)

172 kg

(379 lbs)

4 stroke OHC VTEC in-line 4-cylinder

1,496 cm (91.3 cu-in)

1.0

− 1.3 mm (0.039

− 0.051 in)

Motor-mounted, remote control

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Oil capacity

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear shift

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine:

Gear case:

API standard SG, SH, SJ SAE 10W-30

API standard GL-4 SAE 90 outboard

Engine: motor gear oil

Without oil filter replacement:

4.2

(4.4 US qt , 3.7 Imp qt)

With oil filter replacement:

Gear case:

4.4

(4.6 US qt , 3.9 Imp qt)

0.95

(1.00 US qt , 0.84 Imp qt)

12 V − 35 A

Water cooling with thermostat

Water exhaust

IZFR6K-11E (NGK)

Electric powered mechanical

Automotive unleaded gasoline

(91 research octane, 86 pump octane, or higher)

Dog type: Forward − Neutral − Reverse

30° right and left

− 4° to 16°

68°

(when Transom angle is 12°)

(when Transom angle is 12°)

8°, 12°, 16°, 20°, 24°

* Without battery cable, with propeller

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

147

SPECIFICATIONS

Noise and Vibration

MODELS

CONTROL SYSTEM

Sound Pressure Level At Operator’s Ear

(98/37/EC, ICOMIA 39-94)

Vibration

(98/37/EC, ICOMIA 38-94)

H

82dB

Not Exceed

2 2.5 (m/s ) rms

BF75D

R

75dB

Not Exceed

2 2.5 (m/s ) rms

H

85dB

Not Exceed

2 2.5 (m/s ) rms

BF90D

R

80dB

Not Exceed

2 2.5 (m/s ) rms

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

148

BULGARIA

Kirov Ltd.

49 Tsaritsa Yoana Blvd

1324 Sofia

Tel. : + 359 2 93 30 892

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

honda @ kirov.net

16.

MAJOR Honda DISTRIBUTOR ADDRESSES IN EUROPE

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

AUSTRIA

Honda Austria Gesellschaft

Mbh.

Hondastraße 1

2351 Wiener Neudorf

Tel. : + 43 (0)2236 690 0

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

CANARY ISLANDS

Automocion Canarias, S.A.

Carretera General del Sur, KM. 8,8

38107 Santa Cruz de Tenerife

Tel. : + 34 (922) 620 617

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

ventas @ aucasa.com

taller @ aucasa.com

CZECH REPUBLIC

BG Technik cs, a.s

U Zavodiste 251/8

15900 Prague 5 - Velka Chuchle

Tel. : + 420 2 838 70 850

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

BELGIUM

Honda Motor Europe (North)

Doornveld 180-184

1731 Zellik

Tel. : + 32 2620 10 00

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

BH_PE @ HONDA-EU.COM

CROATIA

Fred Bobek d.o.o.

Honda-Marine Croatia - Trg. - lnd.

zona bb

22211 Vodice

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

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

DENMARK

Tima Products A/S

Tårnfalkevej 16 - Postboks 511

2650 Hvidovre

Tel. : + 45 36 34 25 50

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

CYPRUS

Alexander Dimitriou & Sons Ltd.

162, Yiannos Kranidiotis

Avenue

2235 Latsia, Nicosia

Tel. : + 357 22 715 300

Fax : + 357 22 715 400 http://www.dimitriou.com

FINLAND

OY Brandt AB.

Tuupakantie 7B

01740 Vantaa

Tel. : + 358 207757200

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

FRANCE

HONDA RELATIONS CLIENTS

TSA 80627

45146 St Jean de la Ruelle CEDEX

Tel. : 02 38 81 33 90

Fax : 02 38 81 33 91 http://www.honda.fr

relationsclientele.produitsequipement @ honda-eu.com

GERMANY

Honda Motor Europe (North)

GmbH

Sprendlinger Landstraße 166

63069 Offenbach am Main

Tel. : + 49 (0)69 8300 60

Fax : + 49 (0)69 8300 65100 http://www.honda.de

info @ post.honda.de

GREECE

General Automotive Co S.A.

71, Leoforos Athinon

10173 Athens

Tel. : + 30 210 3483582

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

info @ saracakis.gr

149

MAJOR Honda DISTRIBUTOR ADDRESSES IN EUROPE

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

HUNGARY

Mo.Tor.Pedo Co., Ltd.

Kamaraerdei út 3

2040 Budaörs

Tel. : + 36 23 444 971

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

info @ hondamarine.hu

LITHUANIA

JP Motors Ltd

Kubiliaus str. 6

08234 Vilnius

Tel. : + 370 5 2765259

Fax : + 370 5 2765250 http://www.hondamarine.lt

NORWAY

AS Kellox

Boks 170 - Nygårdsveien 67

1401 Ski

Tel. : + 47 64 97 61 00

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

IRELAND

Two Wheels Ltd.

Crosslands Business Park -

Ballymount Rd

Dublin 12

Tel. : + 353 (0)1 460 2111

Fax : + 353 (0)1 456 6539 http://www.hondaireland.ie

ITALY

Honda Italia Industriale S.p.A.

Via della Cecchignola, 5/7

00143 Roma

Tel. : + 848 846 632

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

info.marine

@ honda-eu.com

MALTA

Associated Motors Company Ltd.

New Street in San Gwakkin Road -

Mriehel Bypass

Mriehel QRM17

Tel. : + 356 21 498 561

Fax : + 356 21 480 150

NETHERLANDS

Honda Nederland Bv

Capronilaan 1

1119 NN Schiphol-Rijk

Tel. : + 31 (0)20 7070000

Fax : + 31 (0)20 7070001 http://www.honda.nl

POLAND

Aries Power Equipment Ltd.

25A Wroclawska Str.

01-493 Warsaw

Tel. : + 48 (22) 685 17 06

Fax : + 48 (22) 685 16 03 http://www.ariespower.com.pl

PORTUGAL

Honda Portugal S.A.

Abrunheira

2714-506 Sintra

Tel. : + 351 21 915 53 33

Fax : + 351 21 915 23 54 http://www.honda.pt

honda.produtos

@ hondaeu.com

REPUBLIC OF

BELARUS

Scanlink Ltd.

Kozlova Drive, 9

220037 Minsk

Tel. : + 375 172 999090

Fax : + 375 172 999900

RUSSIA

Honda Motor Rus LLC

17/2, Krylatskaya Str.

Moscow 121614

Tel. : + 7 (0 95) 745 20 80

Fax : + 7 (0 95) 745 20 81 http://www.honda.co.ru

SLOVAK REPUBLIC

(SLOVAKIA)

Honda Slovakia, s.r.o.

Prievozská 6 - 821 09 Bratislava

Slovak Republic

Tel. : + 421 2 32131112

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

150

MAJOR Honda DISTRIBUTOR ADDRESSES IN EUROPE

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

SPAIN

Greens Power Products S.L.

Poligono Industrial Congost -

Avda. Ramon Ciurans n°2

08530 La Garriga (Barcelona)

Tel. : + 34 (93) 860 50 25

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

UKRAINE

Honda Ukraine LLC

101 Volodymyrska Str. - Build. 2

Kiev 01033

Tel. : + 380 44 390 14 14

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

SWEDEN

Honda Power Equipment

Sweden AB

Box 50583-Västkustvägen 17

20215 Malmö

Tel. : + 46 (0)40 600 23 07

Fax : + 46 (0)40 600 23 19 http://www.hondapower.se

SWITZERLAND

Honda Suisse S.A.

10 Route des Moulières

1214 Vernier-Genève

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

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

UNITED KINGDOM

Honda (UK) Power Equipment

470 London Road

Slough - Berkshire, SL3 8QY

Tel. : + 44 (0)845 200 8000

Fax : + 44 (0)1 753 590 732 http://www.honda.co.uk

customer.servicepe

@ honda-eu.com

151

INDEX

A

ACG Fuse Replacement

Operation

Anode

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

. 137

ACG Indicator/Buzzer

Function ....................................

. 33

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

. 101

Function

Operation

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

. 38

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

. 107

B

Battery

Cleaning ..................................

Connections

. 135

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

. 47

Fluid Level Inspection ............

. 134

Inspection ..................................

Storage ....................................

. 60

. 140

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

. 82

C

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

. 115

Component Identification

Control Panel

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

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

. 13

. 17

Controls and Features

Cooling Water

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

. 21

Check Hole

Intake Port

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

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

. 39

. 39

Cruising

H type

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

. 88

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

. 88

152

R type ........................................

. 90

D

Digital Speedometer

Digital Tachometer

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

. 41

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

. 40

E

Emergency Stop

Switch .................................

Switch Lanyard/Clip ...........

. 23, 30

. 23, 30

Switch Spare Clip .....................

. 31

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

. 133

Engine

Cover

Fixing Lever .........................

. 40

Oil

Removal/Installation ............

. 52

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

Level Inspection

. 120

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

. 53

Refilling ................................

Serial Number

. 53

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

. 3

Switch

H type ....................................

. 21

R type ....................................

. 28

F

Frame Serial Number ......................

. 3

Fast Idle

Button

Lever

Fuel

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

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

Filler Cap ..................................

. 29

. 29

. 41

Filter

Inspection ............................

. 131

Replacement

Line

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

. 131

Connection ............................

Connector and Joint ..............

. 63

. 42

Disconnection

Priming

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

. 113

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

. 65

Tank cleaning

Tank Filter

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

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

. 132

. 132

Fuse Replacement .......................

. 137

G

Gasoline Containing Alcohol .......

. 56

Gear

Shifting ...................

. 83, 84, 85, 86

INDEX

I

Installation

Outboard Motor

Height

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

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

. 45

. 44

Location ....................................

Indicator Panel ..............................

. 44

. 18

L

Lubrication ..................................

. 125

M

Maintenance ................................

Maintenance Schedule ................

Major Honda Distributor

. 116

. 118

Addresses

Manual

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

Relief Valve

. 149

Function

Operation

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

. 37

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

. 99

Moorage ........................................

Motor Angle

. 97

Inspection ..................................

Motor Protection System ............

. 46

. 101

ACG Warning System

Anodes

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

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

. 101

. 107

Oil Pressure Warning System . 101

Overheat Warning System ......

.

. 101

Over-Rev Limiter ...................

. 107

PGM-FI Warning System .......

. 101

Water Contamination

Warning System .................

. 101

N

Neutral Release Lever ...................

. 28

O

Oil Pressure Indicator/Buzzer

Function

Operation

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

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

. 32

. 101

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

Outboard Motor

. 82

Installation ................................

Storage Position ......................

. 45

. 143

Over-Rev Limiter ........................

Overheat Indicator/Buzzer

. 107

Function

Operation

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

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

. 32

. 101

P

PGM-FI Indicator/Buzzer

Function

Operation

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

. 34

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

. 101

Power Tilt Switch

Function

Operation

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

. 36

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

. 98

Power Trim/Tilt Switch

Function

Operation

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

. 35

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

. 88

Pre-operation Checks

Battery

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

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

. 52

. 60

Engine Oil

Fuel

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

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

. 53

. 55

Other Checks ............................

Propeller and Cotter Pin

. 62

Inspection ..............................

Remote Control Lever

. 57

Friction ..................................

Water Separator ........................

. 59

. 60

Propeller

Inspection ..................................

. 57

Replacement

Selection

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

. 138

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

. 51

153

INDEX

R

Remote Control

Box

Identification

Installation

Lever

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

. 16, 17

Installation Location

Cable Length

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

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

. 50

. 50

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

. 49

Function ....................

Friction Adjustment

. 25, 26, 27

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

. 59

S

Safety

Carbon Monoxide Poisoning

Hazard .....................................

. 9

Information .................................

Label Locations ........................

. 7

. 10

Operator Responsibility

Shallow Water Operation

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

...........

. 7

. 108

Shift Lever ....................................

. 21

Spare Clip, Emergency Stop

Switch .................................

. 30, 31

Spark Plugs .................................

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

. 122

. 146

Starting the Engine

Emergency Starting ..................

. 77

H Type

R1 Type

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

. 66

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

. 69

154

R2, R3 Type ..............................

. 73

Steering Handle Friction ...............

Function ....................................

. 59

. 24

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

Stopping the Engine

. 59

Emergency ..............................

Normal Stop

. 109

H Type

R Type

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

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

. 110

. 111

Storage ........................................

Submerged Motor Servicing ......

. 140

. 139

T

Tachometer ...................................

Throttle Friction

. 40

Fixing Dial

Throttle Grip

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

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

. 22

. 22

Tiller Handle .................................

Tiller Handle Height/Angle

. 14

Adjustment ................................

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

. 58

. 37

Tilting the Motor ...........................

Tool Kit and Emergency

. 96

Parts ..................................

. 62, 117

Trailering ....................................

. 114

Transom Height

Transporting

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

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

. 43

. 113

Trim Meter

Function

Operation

Trim Tab

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

. 36

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

. 95

Function ....................................

. 38

Adjustment ..............................

. 100

Trimming the Motor

Troubleshooting

Warning System

Comes On

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

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

. 92

. 144

V

Vapor Separator Draining ...........

. 141

W

Water Separator Buzzer ................

. 34

Water Separator

Cleaning

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

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

. 127

. 127

Wiring Diagram ..........................

. 155

Inside back cover

CONTENTS

TILLER HANDLE TYPE

(For Analogue Meter) .............

. W1

REMOTE CONTROL TYPE

(For Analogue Meter) .............

. W2

REMOTE CONTROL TYPE

(For Digital Meter) ..................

. W3

ABBREVIATIONS

Symbol

A/FSe

ALT

ALTFu

Bat

BF90D

BIMaT

Bz

CKPSe

CoPaAs

DLC

EBTSe

Part name

AIR FUEL RATIO

SENSOR

ALTERNATOR

ALTERNATOR FUSE

(70A)

BATTERY(12V)

BF90D ONLY

BLACK MARKING

TUBE

BUZZER

CRANK SENSOR

CONTROL PANEL

ASSEMBLY

DATA LINK

CONNECTOR

EBT SENSOR

ECTSe1

ECTSe2

EmSw

F

F In 1

F In 2

F In 3

F In 4

FP

FReSe

Fu

Fus

GND

HRMe

IACV

IATSe

IgC 1

IgC 2

IgC 3

IgC 4

IgNr

IgSw

KnSe

Ma

MAPSe

MeHrnA

ECT SENSOR 1

ECT SENSOR 2

EMERGENCY STOP

SWITCH

FUEL

No.1 FUEL INJECTOR

No.2 FUEL INJECTOR

No.3 FUEL INJECTOR

No.4 FUEL INJECTOR

FUEL PUMP

FUEL RESERVE

SENSOR

FUSE

FUSES

GROUND

HOUR METER

IAC VALVE

IAT SENSOR

No.1 IGNITION COIL

No.2 IGNITION COIL

No.3 IGNITION COIL

No.4 IGNITION COIL

IGNITER

ENGINE SWITCH

KNOCK SENSOR

MAIN

MAP SENSOR

METER HARNESS A

WIRING DIAGRAM

MeHrnB

MRL

NSw

OP

OP Sw(H)

METER HARNESS B

PGM-FI MAIN RELAY

NEUTRAL SWITCH

OPTIONAL

OIL PRESSURE SWITCH

(HIGH)

OP Sw(L) OIL PRESSURE SWITCH

(LOW)

PL

PL(M/A)

PL(Ov/OP)

INDICATOR LAMP

INDICATOR LAMP

(MIL, ALTERNATOR)

INDICATOR LAMP

(OVERHEAT, OIL

PT/Tmo

PT/TSw

PRESSURE)

POWER TRIM TILT

MOTOR

POWER TRIM TILT

PTiRL

PTiSw

RAOCV

Re/Re

SpMe

St

StMo

SWITCH

POWER TILT RELAY

POWER TILT SWITCH

ROCKER ARM OIL

CONTROL VALVE

REGULATOR/

RECTIFIER

SPEEDOMETER

STARTER

STARTER MOTOR

155

WIRING DIAGRAM

TDCSe

THA

Tme

TMePCC

ToLtSw

ToSP

ToSPMe

TPSe

TrASe

TRMe

Vme

WLSw

TDC SENSOR

TILLER HANDLE

ASSEMBLY

TACHOMETER

TACHOMETER PULSE

CHECK CONNECTOR

To LIGHT SWITCH

To PLUG

To SPEEDOMETER

TP SENSOR

TRIM ANGLE SENSOR

TRIM METER

VOLTMETER

WATER LEVEL SWITCH

WIRE COLOR CODE

Gr

Lb

Lg

Na

Bl

Br

Bu

G

O

P

R

W

Y

BLACK

BROWN

BLUE

GREEN

GRAY

LIGHT BLUE

LIGHT GREEN

NATURAL

ORANGE

PINK

RED

WHITE

YELLOW

SWITCH CONNECTIONS

IGNITION SWITCH

E IG

COLOR

OFF

ON

START

Bl

Bl/R

BAT

W/Bl

LOAD

Bl/Y

ST

Bl/W

POWER TRIM/TILT SWITCH

Lg W/Bl Lb

UP ○ ○

NORMAL

DOWN ○ ○

EMERGENCY STOP SWITCH

Bl/R Bl

○ ○ PUSH or REMOVE

SWITCH CLIP

SWITCH CLIP

SET

NEUTRAL SWITCH

Bl/Bu

NEUTRAL ○

GEAR IN

POWER TILT SWITCH

Lg W/Bl

○ ○ UP

NORMAL

DOWN ○

Bl

Lb

156

W-1

W-2

W-3

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