Honda BF90D Owner's Manual

08/08/04 18:39:44 31ZY9600_001

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

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

2008 Honda Motor Co., Ltd.

− All Rights Reserved

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

08/08/04 18:39:50 31ZY9600_002

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

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

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

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership.

When your outboard motor needs scheduled maintenance, keep in mind that your Honda Marine dealer is specially trained in servicing Honda outboard motors. Your Honda

Marine dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes,

Honda Motor Co., Ltd.

INTRODUCTION

1

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INTRODUCTION

A FEW WORDS ABOUT

SAFETY

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

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

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

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

Safety Labels − on the outboard motor.

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

and one of

These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

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

Safety Headings − such as IMPORTANT SAFETY INFORMATION.

Safety Section − such as OUTBOARD MOTOR SAFETY.

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

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

2

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

. 7

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

. 7

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

. 9

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

. 10

CONTROL AND FEATURE IDENTIFICATION

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

. 10

COMPONENT AND CONTROL LOCATIONS ....

. 11

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

. 19

LHT Type (tiller handle)

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

. 19

Emergency Stop Switch Clip and Emergency

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

. 19

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

. 20

Throttle Friction Adjuster

Gearshift Lever

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

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

. 21

. 21

Steering Friction Knob ..........................................

. 21

LRT and XRT Types (remote control)

Side-Mount Type

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


. 22

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

. 22

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

. 23

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

. 24

CONTENTS

Panel-Mount Type

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

. 25


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

. 26


. 27

Fast Idle Button

Top-Mount Type

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

. 28

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


. 29

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

. 29


. 30

Fast Idle Button

Common Controls

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

. 32

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

. 33

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

. 34

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

. 34

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

Engine Cover Latch (front/rear) ...........................

. 35

. 35

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

. 35

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

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

. 36

. 36

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

. 36

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

. 36

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

. 37

Fuel Gauge (optional equipment) .........................

. 37

3

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CONTENTS

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

. 38

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

. 38

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

. 39

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

. 40

Cooling System Indicator

OTHER FEATURES

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

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

. 41

. 42

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

. 42

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

. 42

Portable Fuel Tank (optional equipment) .............

. 42

Fuel Priming Bulb (optional equipment) ..............

. 43

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

. 44

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

. 45

ARE YOU READY TO GET UNDERWAY?

.........

. 45

IS YOUR OUTBOARD MOTOR

READY TO GO?

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

. 45

Tiller Handle Height/Angle Adjustment

(LHT type) ........................................................

. 47

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

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

. 48

. 48

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

. 48

PORTABLE FUEL TANK (optional equipment) ....

. 49

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

. 50

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

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

. 51

. 52

LHT Type (tiller handle) .......................................

. 52

LRT and XRT Types (remote control)

Side-Mount Type

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

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

. 55

. 55

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

. 58

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

. 60

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

. 63

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

. 66

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

. 66

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

. 67

GEARSHIFT AND THROTTLE OPERATION .....

. 69

STEERING

CRUISING

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

. 72

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

. 73

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

. 75

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

. 76

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CONTENTS

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

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

. 78

. 78

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

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

. 79

. 80

EMERGENCY STARTER ROPE ...........................

. 80

MAINTENANCE SCHEDULE

TRIM TAB ADJUSTMENT

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

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

. 81

. 83

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

. 84

ENGINE COVER REMOVAL AND

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

. 84

Engine Oil Level Check ........................................

. 85

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

. 86

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

. 87

Engine Oil Recommendations

Spark Plug Service

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

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

. 88

. 89

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

. 92

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

. 94

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

. 95

Water Separator Inspection and Service

Fuel Filter Inspection and Replacement

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

. 96

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

. 99

Portable Fuel Tank and Tank Filter Cleaning

(optional equipment)

Anode Replacement

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

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

. 102

. 103

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

. 103

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

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

. 105

. 105

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

. 105

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

. 107

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

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

. 109

. 109

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

. 109

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

. 110

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CONTENTS

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

WITH OUTBOARD MOTOR

. 111

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

. 111

WITH OUTBOARD MOTOR

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

. 111

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

. 112

HARD STARTING OR STALLS AFTER

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

. 115

ENGINE OVERHEATS .........................................

. 116

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

. 117

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

. 117

Battery Will Not Charge

Fuse Replacement

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

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

. 117

. 117

OIL PRESSURE INDICATOR GOES OFF AND

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

OVERHEAT INDICATOR COMES ON AND

. 119

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

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

. 120

. 122

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

. 122

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

. 123

TECHNICAL AND CONSUMER

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

. 125

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

. 125

Serial Number Locations

Battery

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

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

. 125

. 126

Emission Control System Information

Star Label

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

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

. 126

. 129

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

. 131

CONSUMER INFORMATION

Honda Publications

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

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

. 134

. 134

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

. 134

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

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

. 137

. 141

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

. 145

6

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IMPORTANT SAFETY

INFORMATION

The Honda BF75D/BF90D outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

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

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

OUTBOARD MOTOR SAFETY

Operator Responsibility

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

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

Understand the use of all controls.

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

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

Attach the emergency stop switch lanyard securely to the operator.

Always wear a PFD (Personal

Flotation Device) while on the boat.

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

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

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

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

7

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Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode.

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

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

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

Carbon Monoxide Hazard

Exhaust gas contains poisonous carbon monoxide. Do not inhale exhaust gas. Never run the engine in a closed garage or confined area.

8

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SAFETY LABEL LOCATION


FUEL TANK

[optional equipment (LHT type)]

The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Honda

Marine dealer for a replacement.

9

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CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model BF75D

Type LHT LRT

Transom Height

(Shaft Length)

21.1 in (537 mm)

26.1 in (664 mm)

Tiller Handle

Remote Control

Power Trim/Tilt

Trim Meter (optional equipment)

Tachometer (optional equipment)

LHT

BF90D

LRT

10

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

TYPE CODE (example)

L R T

Tilt System

T = Power Trim/Tilt

Control System

H = Tiller Handle

R = Remote Control

Transom Height (Shaft Length)

L = 21.1 in (537 mm)

X = 26.1 in (664 mm)

XRT

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COMPONENT AND CONTROL LOCATIONS

LHT Type (tiller handle)

ENGINE COVER

ENGINE COVER

LATCH (front)

OIL LEVEL DIPSTICK

SPARK PLUG

(under coil)

TILLER

HANDLE

STERN

BRACKET

MANUAL

RELIEF VALVE

ENGINE COVER

LATCH (rear)

IDLE PORT

POWER TILT

SWITCH

COOLING SYSTEM

INDICATOR

ANODE

(each side)

FLUSH PORT

CONNECTOR

TRIM TAB

ENGINE OIL

DRAIN BOLT

ANODE

EXHAUST PORT/WATER

OUTLET PORT

ANTIVENTILATION

PLATE

PROPELLER

(optional equipment)

OIL FILLER CAP

TILT LOCK

LEVER

PRODUCT

IDENTIFICATION

NUMBER

GEAR OIL

LEVEL SCREW

COOLING WATER

INTAKE PORT

(each side)

GEAR OIL DRAIN SCREW

11

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INDICATORS

(Oil pressure, Overheat,

Alternator, PGM-FI)

EMERGENCY STOP

SWITCH

EMERGENCY STOP

SWITCH CLIP

EMERGENCY STOP

SWITCH LANYARD

GEARSHIFT LEVER

THROTTLE FRICTION

ADJUSTER

12

IGNITION SWITCH

STEERING FRICTION

KNOB

POWER TRIM/TILT

SWITCH

THROTTLE GRIP

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Portable Fuel Tank and Fuel Tank Hose Assembly



FUEL FILLER CAP VENT KNOB

FUEL TANK

FUEL HOSE

CONNECTOR

FUEL GAUGE

FUEL PRIMING BULB

FUEL TANK HOSE

ASSEMBLY

FUEL HOSE JOINT

(motor side)

13

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LRT and XRT Types (remote control)

ENGINE COVER

ENGINE COVER

LATCH (front)

STERN

BRACKET

MANUAL

RELIEF VALVE


ENGINE COVER

LATCH (rear)

SPARK PLUG

(under coil)

POWER TILT

SWITCH

IDLE PORT

COOLING SYSTEM

INDICATOR

FLUSH PORT

CONNECTOR

ANODE

(each side) ENGINE OIL

DRAIN BOLT

TRIM TAB

ANODE

PROPELLER

EXHAUST PORT/WATER

OUTLET PORT


ANTIVENTILATION

PLATE

14

OIL FILLER CAP

TILT LOCK

LEVER

PRODUCT

IDENTIFICATION

NUMBER

GEAR OIL

LEVEL SCREW

COOLING WATER

INTAKE PORT

(each side)

GEAR OIL DRAIN SCREW

08/08/04 18:41:16 31ZY9600_016


Remote Controls (optional equipment)

(SIDE-MOUNT REMOTE CONTROL)

GEARSHIFT/THROTTLE

CONTROL LEVER

NEUTRAL RELEASE

LEVER

(PANEL-MOUNT REMOTE CONTROL)


CONTROL LEVER

NEUTRAL RELEASE

LEVER

POWER TRIM/TILT

SWITCH

OIL PRESSURE

INDICATOR

OVERHEAT

INDICATOR

POWER TRIM/TILT

SWITCH

SPARE SWITCH

CLIP

BUZZER

(inside)

FAST IDLE

LEVER

IGNITION

SWITCH

FAST IDLE BUTTON

CONTROL PANEL

(for PANEL-MOUNT type)

CONTROL LEVER

FRICTION ADJUSTER

LANYARD

EMERGENCY

STOP SWITCH

SWITCH CLIP

BUZZER

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

LANYARD

OIL PRESSURE

INDICATOR

OVERHEAT

INDICATOR

EMERGENCY

STOP SWITCH

15

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(SINGLE TOP-MOUNT REMOTE CONTROL)


CONTROL LEVER

(DUAL TOP-MOUNT REMOTE CONTROL)


CONTROL LEVERS

POWER TRIM/TILT

SWITCH (RIGHT)

POWER

TRIM/TILT

SWITCH

POWER TRIM/TILT

SWITCH (LEFT)

FAST IDLE

BUTTON

CONTROL PANEL

(for TOP-MOUNT SINGLE type)

BUZZER

IGNITION

SWITCH

EMERGENCY STOP

SWITCH CLIP

LANYARD

OIL PRESSURE

INDICATOR

OVERHEAT

INDICATOR

EMERGENCY

STOP SWITCH

FAST IDLE

BUTTON

(for TOP-MOUNT DUAL type)

16

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Indicator Panel

(standard equipment)

ALTERNATOR (ACG)

INDICATOR


Fuel Hose Assembly


FUEL HOSE

ASSEMBLY

FUEL HOSE JOINT

(fuel tank side)

PROGRAMMED FUEL

INJECTION (PGM-FI)

INDICATOR

FUEL PRIMING BULB

FUEL HOSE JOINT

(motor side)

17

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Trim Meter


Tachometer


Digital Speedometer


Digital Tachometer


18

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CONTROLS


Ignition Switch

O N

START

O F F


Turning the ignition switch key to the

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

The engine will not start unless the gearshift lever is in the N (neutral)

position (p.

52 ) and the emergency

stop switch clip is in the emergency stop switch.

Turning the ignition switch to the

OFF position stops the engine.

Emergency Stop Switch Clip and

Emergency Stop Switch

EMERGENCY STOP SWITCH

EMERGENCY STOP

SWITCH CLIP

LANYARD

IGNITION SWITCH

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

EMERGENCY STOP SWITCH CLIP

LANYARD

19

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

(Personal Flotation Device).

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

A spare switch clip is provided in the

tool bag (p.

80 ).

Throttle Grip

THROTTLE GRIP

INCREASE

THROTTLE INDEX MARK

The throttle grip controls engine speed.

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

starting (p.

69 ).

20

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Throttle Friction Adjuster

THROTTLE FRICTION

ADJUSTER


Gearshif t Lever

N (neutral)

R (reverse)

Steering Friction Knob

STEERING FRICTION KNOB

FIX

F

(forward)

R E L E A S E

RELEASE

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.

GEARSHIFT

LEVER

The gearshift lever is used to select F

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

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

FIX

The steering friction adjuster adjusts steering resistance.

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

21

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LRT and XRT Types

(remote control)

Side-Mount Type


O F F

O N

START



The ignition switch can be used to start the engine only when the control lever is in the N (neutral) position (p.

55 ) and the emergency stop switch

clip is in the emergency stop switch.






EMERGENCY STOP

SWITCH CLIP

LANYARD

IGNITION

SWITCH


EMERGENCY STOP

SWITCH CLIP

LANYARD

22

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

Device) or to the operator securely.

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

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

provided in the tool bag (p.

80 ).

SPARE SWITCH CLIP


Gearshif t/Throttle Control

Lever


CONTROL LEVER

NEUTRAL RELEASE

LEVER

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


23

08/08/04 18:42:25 31ZY9600_025


T H R O

F (FORWARD)

N (NEUTRAL)

30° 30°

SHIFT SHIFT

T T L E O P E

M

N I

I

N

N

G

I M U M

R (REVERSE)

M I N I M U M

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

MAXIMUM

Fast Idle Lever

FAST IDLE LEVER

MAXIMUM


CONTROL LEVER

Moving the control lever 30° from N

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

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

A friction adjuster near the base of the control lever(s) adjusts the operating resistance of the control

lever(s). Refer to p.

71

.

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

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

See page 57

for engine warm-up instructions.

24

08/08/04 18:42:32 31ZY9600_026

N (neutral)

MAXIMUM FAST IDLE

Panel-Mount Type


ON

START

LOWEST

POSITION

FAST IDLE LEVER

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

OFF

IGNITION

SWITCH










25

08/08/04 18:42:39 31ZY9600_027









tool bag (p.

80 ).


EMERGENCY STOP

SWITCH CLIP

LANYARD

EMERGENCY STOP

SWITCH CLIP

26

LANYARD

08/08/04 18:42:47 31ZY9600_028


Lever


CONTROL LEVER


T H R O T T L

F (FORWARD)

35°

N (NEUTRAL)

35°

SHIFT SHIFT

E O P E N I N

M

G

I N I M U M

R (REVERSE)

M I N I M U M


MAXIMUM

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


NEUTRAL

RELEASE

LEVER

MAXIMUM



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


CONTROL LEVER

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

to p.

71 .


27

08/08/04 18:42:56 31ZY9600_029


Fast Idle Button


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

See page 59


F (forward)

CONTROL

LEVER

Push

N (neutral)

R (reverse)

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

Return the control lever to N position to cancel the fast idle operation.

P u l l u p

NEUTRAL

RELEASE

LEVER


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

28

08/08/04 18:43:04 31ZY9600_030

Top-Mount Type


START

ON

OFF

IGNITION

SWITCH













EMERGENCY STOP

SWITCH CLIP

LANYARD

EMERGENCY STOP

SWITCH CLIP

LANYARD

29

08/08/04 18:43:11 31ZY9600_031






tool bag (p.

80 ).


Lever

SINGLE TYPE

DUAL TYPE

GEARSHIFT/

THROTTLE

CONTROL

LEVER

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


30



CONTROL LEVERS

08/08/04 18:43:17 31ZY9600_032




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

p.

71 .


F (FORWARD)

35°

SHIFT

N (NEUTRAL)

35°

SHIFT

R (REVERSE)

M I N I M U M


M I N I M U M


MAXIMUM

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

31

08/08/04 18:43:24 31ZY9600_033


Fast Idle Button

F (forward)

N (neutral)

R (reverse)

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

Return the control lever to N position to cancel the fast idle operation.

CONTROL

LEVER


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

See page 62


Push


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

32

08/08/04 18:43:33 31ZY9600_034


Common Controls

Power Trim/Tilt Switch

(tiller handle/control lever side)

LHT Type

LRT and XRT Types

(side-mount type)

POWER TRIM/

TILT SWITCH

(top-mount type)

SINGLE TYPE

POWER TRIM/TILT SWITCH

POWER

TRIM/TILT

SWITCH

CONTROL

LEVER

CONTROL

LEVER

(panel-mount type)


CONTROL LEVER

DUAL TYPE


(LEFT) (RIGHT)

C O N T R O L

L E V E R S

33

08/08/04 18:43:43 31ZY9600_035


The power trim/tilt switch is located on the control lever. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the motor angle.

Trim the outboard motor to obtain the best performance and stability

(p.

73 ).

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

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

Power Tilt Switch

(engine pan side)

POWER TILT SWITCH

The power tilt switch is located on the engine pan. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

The power tilt switch will operate without turning the ignition switch

ON.

This switch is used with the engine stopped to raise the outboard motor for mooring, trailering, or maintenance.

34

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 )

M A N U A L R E L I E F V A L V E

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

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

08/08/04 18:43:53 31ZY9600_036

Tilt Lock Lever

F R E E

Engine Cover Latch

(front/rear)

ENGINE COVER

LATCHES

(front/rear)


Trim Tab

GEAR CASE

GROMMET

L O C K

U N L A T C H

STERN BRACKET

TILT LOCK LEVER

The tilt lock lever is used to support the outboard motor in the fully-raised position.

When the boat is to be moored for a long time, tilt the outboard motor up as far as it will go. Then move the tilt lock lever to the LOCK position, and gently lower the outboard motor until the lever contacts the stern bracket.

F I X

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

TRIM TAB

TRIM TAB BOLT

The trim tab compensates for

‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly

adjusted (p.

83 ), steering effort is

equal in either direction.

35

08/08/04 18:44:07 31ZY9600_037


INSTRUMENTS

Trim Meter


Tachometer




TRIM METER

The trim meter indicates the relative trim angle of the outboard motor.

Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat.

TACHOMETER

The tachometer shows engine speed in revolutions per minute.

Refer to the tachometer when using the throttle and power trim/tilt controls to achieve the best performance from the boat.

Digital Tachometer includes the following functions.

Tachometer

Hour Meter

Trim Meter

Oil Pressure Indicator

Overheat Indicator

ACG Indicator

PGM-FI Indicator

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

36

08/08/04 18:44:19 31ZY9600_038



Fuel Gauge

[optional equipment

(LHT type)]


Digital Speedometer includes the following functions.

Speedometer

Fuel Level Meter

Voltmeter

Tripmeter

Fuel Integration Meter

Fuel Economy Meter

Fuel Flow Meter

Water Separator Indicator

Refer to the Operation Guide included with the Digital

Speedometer for operation information.

FUEL GAUGE

A fuel gauge is built into the cap of the portable fuel tank (optional equipment).

37

08/08/04 18:44:28 31ZY9600_039


INDICATORS

Alternator (ACG) Indicator

LHT Type

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

Programmed Fuel Injection

(PGM-FI) Indicator

LHT Type

ACG INDICATOR

(internal buzzer)


ACG INDICATOR

PGM-FI

INDICATOR



PGM-FI INDICATOR

38

(Indicator panel) (Indicator panel)

08/08/04 18:44:39 31ZY9600_040

When the engine control system detects a PGM-FI malfunction, the

PGM-FI indicator turns on and the buzzer sounds at one-second intervals.

Under normal conditions, when the ignition key is turned on the following will occur:

1.

Both the PGM-FI indicator and

2.

ACG indicator will turn on.

The buzzer will beep twice.

3.

4.

The PGM-FI indicator will turn off shortly after the second beep.

The ACG indicator will turn off after the engine starts.

Oil Pressure Indicator

LHT Type

OIL PRESSURE

INDICATOR

(GREEN)





(GREEN)

BUZZER

(panel-mount/top-mount types)

(GREEN)

BUZZER

39

08/08/04 18:44:49 31ZY9600_041


When the oil pressure indicator is lit, oil pressure is OK.

If oil pressure becomes low, the indicator will go off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF

UNEXPECTED PROBLEMS,

on p.

119

.

All models are equipped with a buzzer that sounds continuously when the oil pressure indicator goes off.

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

Overheat Indicator

LHT Type

OVERHEAT

INDICATOR

(RED)




(RED)

(panel-mount/top-mount types)

(RED)

BUZZER

BUZZER

40

08/08/04 18:44:55 31ZY9600_042

When the alert triggers, the overheat indicator comes on and the buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine shuts off. Refer to

p.

TAKING CARE OF

UNEXPECTED PROBLEMS , on

120 .

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

Engine overheating may be the result of clogged water intakes.

Cooling System Indicator

COOLING SYSTEM INDICATOR

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

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

The cooling system indicator discharge port can also become plugged.


41

08/08/04 18:45:05 31ZY9600_043


OTHER FEATURES

Water Separator Buzzer

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

Overrev Limiter

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

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

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

Check to see if the correct propeller is installed.

WATER SEPARATOR

Portable Fuel Tank


(LHT type)]

FUEL TANK

FUEL HOSE

The portable fuel tank has a capacity of 6.6

US gal ( 25 L) and has a fuel gauge built into the cap.

42

08/08/04 18:45:13 31ZY9600_044

Fuel Filler Cap Vent Knob


(LHT type)]

VENT KNOB

C L O S E

O P E N


Fuel Priming Bulb


UP

OUTLET END

(motor side)

FUEL FILLER CAP

The fuel filler cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat. Open the vent knob 2 or 3 turns before starting the engine.

PRIMING BULB

INLET END

(tank side)

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

Before starting the engine, hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the

engine (p.

51 ).

43

08/08/04 18:45:18 31ZY9600_045


Anodes

ANODE

(each side)

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

There are two anodes on the gear case, one on the stern bracket and two small anodes in the water passages of the engine block.

44

ANODE

(stern bracket)

08/08/04 18:45:28 31ZY9600_046

ARE YOU READY TO GET

UNDERWAY?

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

Knowledge

Read and understand this manual.

Know what the controls do and how to operate them.

Familiarize yourself with the outboard motor and its operation before you get underway. Know what to do in case of an emergency.

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

BEFORE OPERATION

Safety

Always wear a PFD (Personal

Flotation Device) while on the boat.

Attach the emergency stop switch clip securely to the operator or to the operator’s PFD (Personal Flotation

Device).

IS YOUR OUTBOARD

MOTOR READY TO GO?

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

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

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

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

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

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

45

08/08/04 18:45:40 31ZY9600_047


Safety Inspection

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

If you are using the portable fuel tank (optional equipment), make sure it is in good condition and properly secured in the boat

(p.

49 ).

Check that the fuel hose is undamaged and properly connected.

Wipe up any spills before starting the engine.

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

Check that all controls are operating properly.

Replace any damaged parts.

Check that all fasteners are in place and securely tightened.

Check the emergency stop switch for proper operation. Start the

engine (p.

22 ,

26

or

29 ). Make

sure the engine stops by pulling the emergency stop switch clip from the emergency stop switch

(p.

66 ).

Maintenance Inspection

Check the engine oil level (p.

85 ).

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

Check to be sure the propeller is undamaged and the castle nut is secured with the cotter pin

(p.

104 ).

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

the gear case (p.

103 ) and are not

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

46

Make sure a tool kit and the emergency starter rope are

onboard (p.

80 ). Replace any

missing items.

Check the fuel level in the fuel

tank (p.

94 ).

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

Check the water separator for

water contamination (p.

96 ).

08/08/04 18:45:50 31ZY9600_048

Tiller Handle Height/Angle

Adjustment (LHT 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.

1.

Raise the tiller handle and remove the 8 × 28 mm flange bolt and the height adjustment block.

2.

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.

HEIGHT ADJUSTMENT

BLOCK

8 × 28 mm

FLANGE BOLT

11.7 in

(296 mm)





14.1 in

(359 mm)


17.0 in

(433 mm)

HEIGHT

Reference point

47

08/08/04 18:46:01 31ZY9600_049

OPERATION

SAFE OPERATING

PRECAUTIONS

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

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

IMPORTANT SAFETY

INFORMATION chapter titled

on page 7

and the

BEFORE OPERATION.

For your safety, do not start or operate the engine in an enclosed area. Your engine’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

BREAK-IN PROCEDURE

Break-in period: 10 hours

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

First 15 minutes:

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

Next 45 minutes:

Run the engine up to a maximum of

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

10% to 30% of maximum throttle opening.

Next 60 minutes:

Run the engine up to a maximum of

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

50% to 80% of maximum throttle opening.

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

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

Next 8 hours:

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

48

08/08/04 18:46:10 31ZY9600_050

PORTABLE FUEL TANK


(LHT type)]

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

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

3 turns counterclockwise.

Place the portable fuel tank (optional equipment) in a well-ventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.

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

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

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

Handle fuel only outdoors.

Wipe up spills immediately.

OPERATION

49

08/08/04 18:46:18 31ZY9600_051

OPERATION

FUEL HOSE CONNECTIONS

HOSE PLUG

FUEL HOSE

ASSEMBLY

1.

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

Store the hose plug in a secure place.

FUEL

HOSE

HOSE

CLAMP

FUEL HOSE

(motor side)

FUEL HOSE

JOINT

BARB

FUEL HOSE CONNECTOR

(fuel tank side)

2.

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

HOSE CLAMP

(stainless steel)

ARROW

(outboard motor side)

PRIMING

BULB

50

08/08/04 18:46:29 31ZY9600_052

OPERATION

(Using the fuel tank mounted on the boat)

FUEL HOSE ASSEMBLY


(motor side)

FUEL PRIMING

UP

OUTLET END

(motor)

FUEL HOSE

(tank side)

PRIMING BULB

BARB

HOSE CLAMP

(stainless steel)

(FUEL TANK SIDE)

1.

Remove the hose plug from the motor side fuel hose. Insert the fuel hose joint into the motor side fuel hose and secure it with the

hose clamp. (Refer to the page 50 .)

2.

Insert another fuel hose 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.

INLET END

(tank)

Hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine.

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

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






51

08/08/04 18:46:37 31ZY9600_053

OPERATION

STARTING THE ENGINE

Control Page

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

. 55

Panel-Mount Type

Top-Mount Type

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

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

. 58

. 60

LHT Type (tiller handle)


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

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

Always attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine.

N (neutral)

GEARSHIFT LEVER

2.

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

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

EMERGENCY STOP

SWITCH CLIP

LANYARD

1.

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

Flotation Device).

52

08/08/04 18:46:46 31ZY9600_054

OPERATION

START

POSITION

POINTER

O F F

O N S T A R T

THROTTLE GRIP

3.

Align the engine start symbol

‘‘ ’’ on the tiller handle with the pointer ‘‘ ’’ on the throttle grip.

4.

Turn the ignition switch key to the

ON position; the buzzer will sound two times.

IGNITION SWITCH KEY

5.


START position and hold it there until the engine starts.

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

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

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

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

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

SLOW position without stalling.

53

08/08/04 18:46:53 31ZY9600_055

OPERATION

6.

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

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

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

2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.

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

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

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

During the warm-up period, check

the oil pressure indicator (p.

39 ),

overheat indicator (p.

40 ), and

cooling system indicator (p.

41 ).

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

TAKING CARE OF

UNEXPECTED PROBLEMS

p.

119 − 122 .

on

54

08/08/04 18:47:01 31ZY9600_056


(remote control)

Side-Mount Type


EMERGENCY STOP

SWITCH CLIP

LANYARD

1.

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

Device).

OPERATION




CONTROL

LEVER

N (neutral)

2.

Set the control lever in the N

(neutral) position.

The engine will not start if the F

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

55

08/08/04 18:47:10 31ZY9600_057

OPERATION

LOWEST

POSITION

O F F

ON

START

FAST IDLE RANGE

3.

Leave the fast idle lever in the

OFF (fully lowered) position.

The fast idle lever cannot be raised unless the control lever is in the N

(neutral) position.

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

4.



56

IGNITION SWITCH KEY

5.







08/08/04 18:47:19 31ZY9600_058

MAXIMUM FAST IDLE

FAST IDLE

RANGE

6.




2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.




OPERATION



39 ),


40 ), and


41 ).


TAKING CARE OF


p.

119 − 122 .

on

7.

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

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

57

08/08/04 18:47:27 31ZY9600_059

OPERATION



EMERGENCY STOP

SWITCH CLIP

LANYARD

1.


Flotation Device).




CONTROL

LEVER

N (neutral)

2.


(neutral) position.



3.



58

08/08/04 18:47:35 31ZY9600_060

OPERATION

OFF

ON

START

IGNITION

SWITCH

KEY

4.





N (neutral)



CONTROL

LEVER


5.




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

59

08/08/04 18:47:42 31ZY9600_061

OPERATION






39 ),


40 ), and


41 ).


TAKING CARE OF


p.

119 − 122 .

on

6.

If the fast idle button was used to warm up the engine, gradually return the control lever to the N

(neutral) position as the engine warms up.

Top-Mount Type

EMERGENCY STOP

SWITCH

EMERGENCY STOP

SWITCH CLIP

LANYARD

1.


Flotation Device).

60

08/08/04 18:47:51 31ZY9600_062

OPERATION




CONTROL

LEVER

N (neutral)

OFF

ON

IGNITION

SWITCH

KEY

START

2.


(neutral) position.



3.



4.





61

08/08/04 18:47:58 31ZY9600_063

OPERATION

N (neutral)

62



CONTROL

LEVER


5.




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




08/08/04 18:48:09 31ZY9600_064



39 ),


40 ), and


41 ).


TAKING CARE OF


p.

119 − 122 .

on

6.

If the fast idle button was used to warm up the engine, gradually return the control lever to the N

(neutral) position as the engine warms up.

EMERGENCY STARTING

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

ENGINE COVER

LATCHES

(front/rear)

UNLOCK

1.

Turn the engine switch key to the

OFF position.

2.

Unlatch and remove the engine cover.

6 mm WASHER

CLAMP

HOOKS

OPERATION

6 × 25 mm

FLANGE BOLT

ALTERNATOR

COVER

CLAMPS

BREATHER

TUBE

CLAMP (on the silencer case)

3.

Release the breather tube from the four clamps.

4.

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

5.

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

Take care not to lose the bolt and washer.

63

08/08/04 18:48:16 31ZY9600_065

OPERATION

6.

Set the controls the same as for normal starting (see pages

52 −

,

− ,

). Use the fast

idle control if needed.


ON position.

EMERGENCY

STARTER ROPE

KNOT

ALTERNATOR PULLEY

7.

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

8.

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

Keep away from moving parts while pulling the rope.

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

TAKING CARE OF


from p.

112 .

64

08/08/04 18:48:23 31ZY9600_066

9.

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



39 ),


40 ), and


41 ).

10.

Leave the alternator cover off, but

install the engine cover (p.

84 )

and lock it in place by latching the engine cover latch.

11.

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

12.

Have your closest authorized

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

Exposed moving parts can cause injury.

Do not operate the outboard motor without the engine cover.

Use extreme care when installing the engine cover.

OPERATION

65

08/08/04 18:48:33 31ZY9600_067

OPERATION

STOPPING THE ENGINE

Emergency Engine Stopping



PULL



Side-Mount Type


LANYARD

PULL

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

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


OFF position after verifying the emergency stop switch operation.

EMERGENCY STOP

SWITCH CLIP

LANYARD

EMERGENCY STOP

SWITCH CLIP

Panel-Mount/Top-Mount Types

EMERGENCY

STOP SWITCH CONTROL PANEL

PULL

LANYARD

EMERGENCY STOP SWITCH CLIP

66

08/08/04 18:48:42 31ZY9600_068

Normal Engine Stopping




Side-Mount Type

N (neutral)

SLOW

CONTROL

LEVER

THROTTLE GRIP

N (neutral)


N (neutral)

CONTROL

LEVER

GEARSHIFT LEVER

OPERATION

Top-Mount Type

N (neutral)

CONTROL

LEVER

1.

Move the throttle grip to the slowest speed and the gearshift lever or control lever to the N

(neutral) position.

67

08/08/04 18:48:51 31ZY9600_069

OPERATION


O F F

IGNITION

SWITCH KEY



Side-Mount Type

O F F

Panel-Mount/Top-Mount Types

O F F

IGNITION

SWITCH KEY

2.

3.


OFF position to stop the engine.

In the event that the engine does not stop when the ignition switch key is turned to OFF, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch

lanyard (p.

66 ).

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

IGNITION

SWITCH KEY

68

08/08/04 18:48:59 31ZY9600_070

OPERATION

GEARSHIFT AND

THROTTLE OPERATION


POINTER

THROTTLE

GRIP

SLOW

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

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

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

The throttle grip can be turned to the

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

FAST

GEARSHIFT

LEVER N

(neutral)

R

(reverse)

F

(forward)

THROTTLE FRICTION ADJUSTER

THROTTLE

GRIP

FIX

RELEASE

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

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

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

69

08/08/04 18:49:09 31ZY9600_071

OPERATION



Side-Mount Type

CONTROL LEVER

N (neutral)

NEUTRAL

RELEASE

LEVER


N (neutral)

F (forward)

CONTROL

LEVER

R (reverse)

NEUTRAL

RELEASE

LEVER

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

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

(side-mount/panel-mount types).

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

Top-Mount Type

N (neutral)

F (forward)

R (reverse)

F (forward)

70

R (reverse)

CONTROL

LEVER

08/08/04 18:49:16 31ZY9600_072

Side-Mount Type Top-Mount Type

TO INCREASE

FRICTION

CONTROL

LEVER

FRICTION

ADJUSTER

TO DECREASE

FRICTION


CONTROL LEVER


TO INCREASE

FRICTION

TO INCREASE

FRICTION

TO DECREASE

FRICTION

CONTROL LEVER


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

TO DECREASE

FRICTION

OPERATION

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08/08/04 18:49:24 31ZY9600_073

OPERATION

STEERING


RIGHT TURN LEFT TURN


D E C R E A S E

F R I C T I O N



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.

I N C R E A S E

F R I C T I O N

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.

72

08/08/04 18:49:35 31ZY9600_074

OPERATION

CRUISING

Engine Speed

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

throttle friction control (p.

69 −

to help you hold a steady speed.

71 )

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

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

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

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

Trim

Use the power trim/tilt switch to trim the outboard motor for the best performance and stability.

You can use the power trim/tilt switch at any time, whether the boat is underway or stopped.

Press the UP or DN (down) side of the switch to adjust the angle of the outboard motor.

Refer to the trim meter (p.

36 ) for an

indication of whether the motor is trimmed high or low.

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

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

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

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

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

73

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OPERATION

LHT Type (tiller handle) Panel-Mount Type


CONTROL LEVER

MOTOR

TRIMMED TOO

LOW

MOTOR

TRIMMED TOO

HIGH

POWER TRIM/

TILT SWITCH



Side-Mount Type

POWER

TRIM/TILT

SWITCH

74

CONTROL

LEVER

MOTOR TRIMMED

CORRECTLY

Top-Mount Type

(single type)

POWER TRIM/TILT

SWITCH

(dual type)


(LEFT) (RIGHT)

CONTROL

LEVER

BOW TOO LOW DUE TO

1. LOAD IN THE FRONT

2. MOTOR TRIMMED TOO LOW

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. MOTOR TRIMMED TOO HIGH

CONTROL

LEVER

08/08/04 18:49:57 31ZY9600_076

If steering effort is not equal in both directions, adjust the trim tab to compensate for ‘‘torque steer,’’ which is the reaction of the outboard motor to propeller rotation.

GEAR CASE GROMMET

TRIM TAB

TRIM TAB BOLT

Adjust the trim tab with the engine stopped. Remove the gear case grommet. Loosen the bolt above the trim tab, turn the trim tab, and then tighten the bolt and install the gear case grommet securely.

OPERATION

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

Refer to

on p.

83 .

TRIM TAB ADJUSTMENT

SHALLOW WATER

OPERATION

When operating in shallow water, use

the power trim/tilt switch (p.

74 ) to

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

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

indicator (p.

41 ) to be sure the

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

An excessive trim/tilt angle during operation can cause propeller ventilation, overheating, and water pump damage. This type of damage is not covered by the

Limited Warranty

(p.

Distributor’s

137 ).

68°

12°

TILT

ANGLE

0°

16°

− 4°

0°

(VERTICAL LINE)

TRIM ANGLE

(transom angle at 12°)

75

08/08/04 18:50:04 31ZY9600_077

OPERATION

MOORING, BEACHING,

LAUNCHING

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

To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch on the engine pan to tilt the outboard motor up as far as it will go.

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

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

POWER TILT SWITCH

F R E E

L O C K

STERN BRACKET

TILT LOCK LEVER

(lock position)

TRIM RODS

76

08/08/04 18:50:09 31ZY9600_078

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 ) motor will tilt up when operated in reverse.

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

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

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the engine.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard

OPERATION

77

08/08/04 18:50:16 31ZY9600_079

SERVICING YOUR OUTBOARD MOTOR

THE IMPORTANCE OF

MAINTENANCE

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

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

Always follow the inspection and maintenance recommendations and schedules in this Owner’s

Manual.

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

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

Remember that your authorized

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

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

Genuine parts or their equivalents for repair and replacement.

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

EPA standards.

78

08/08/04 18:50:25 31ZY9600_080


MAINTENANCE SAFETY

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

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

Always follow the procedures and precautions in the Owner’s

Manual.

Safety Precautions

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

− Carbon monoxide poisoning from engine exhaust.

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

− Burns from hot parts.

Let the engine and exhaust system cool before touching.

− Injury from moving parts.

Do not run the engine unless instructed to do so.

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

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

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

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08/08/04 18:50:33 31ZY9600_081


TOOL KIT and OWNER’S MANUAL

10 × 14 mm WRENCH SPARK PLUG WRENCH

EMERGENCY STARTER

ROPE

8 × 12 mm WRENCH 18 × 19 mm BOX WRENCH

OIL CHECK

SCREWDRIVER

PHILLIPS/FLAT

SCREWDRIVER

SCREWDRIVER

HANDLE

10 mm BOX WRENCH

PLIERS

FUSE PULLER

TOOL BAG OWNER’S MANUAL

SPARE EMERGENCY

STOP SWITCH CLIP

The tool kit can be used for simple maintenance procedures and emergency repairs. Keep these items on the boat so that they will always be available if you need them.

Always carry a spare emergency stop switch clip onboard. The spare clip may either be stored in the tool bag or in an easily accessible location on the boat.

If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually.

80

EMERGENCY STARTER ROPE

An emergency starter rope is supplied. Keep the emergency starter rope on the boat, so it will always be available if you need it.

08/08/04 18:50:44 31ZY9600_082


MAINTENANCE SCHEDULE

Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim for warranty coverage will not be denied simply because the maintenance schedule for your outboard was not followed.

However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance, would not be covered under the Distributor’s Limited Warranty .

REGULAR SERVICE PERIOD (3)

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

Each use After use

First month or

20 hrs.

Every 6 months or

100 hrs.

Every year or

200 hrs.

Every 2 years or

400 hrs.

Refer to page

ITEM

Engine oil

Gear case oil

Engine oil filter

Throttle linkage

Idle speed

Valve clearance

Spark plugs

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

○

○

○

○

○

○ (2)

○

○

(2)

(2)

○ (1)

○

○ (2)

○

○

(2)

(2)

○ (1)

○ (2)

○ (2)

○

○ (2)

○

85

86

87

89 − 91

104

103

92, 93

96 − 99

(1)

(2)

(3)

Lubricate more frequently when used in salt water.

These items should be serviced by an authorized Honda Marine dealer, unless you have the proper tools and are mechanically proficient.

Refer to the Honda shop manual for service procedures.

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

81

08/08/04 18:50:56 31ZY9600_083


REGULAR SERVICE PERIOD (3)

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

Each use After use

First month or

20 hrs.

Every 6 months or

100 hrs.

Every year or

200 hrs.

Every 2 years or

400 hrs.

Refer to page

ITEM

Fuel filter

(Low pressure side)

Fuel filter

(High pressure side)

Thermostat

Fuel tank and tank filter

Fuel line

Check

Replace

Check

Replace

Check

Clean

Check

Replace

Check level-tightness

○

○

○ (2)

Every 2 years (If necessary) (2)

○ (2)

○

○

○ (2)

99 − 101

102

Battery and cable connection

Bolts and nuts

Breather tube

Cooling water passages

Water pump

Emergency stop switch

Check-tightness

Check

Clean

Check

Check

○

○ (4)

○ (2) ○ (2)

○ (2)

○ (2)

○

46

(1)

(2)

(3)

(4)

Lubricate more frequently when used in salt water.

These items should be serviced by an authorized Honda Marine dealer, unless you have the proper tools and are mechanically proficient.

Refer to the Honda shop manual for service procedures.

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

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

82

08/08/04 18:51:06 31ZY9600_084


TRIM TAB ADJUSTMENT

The trim tab compensates for

‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted, steering effort is equal in either direction.

If steering effort is unequal, remove the gear case grommet and loosen the trim tab bolt then adjust the angle of the trim tab. Retighten the trim tab bolt and reinstall the gear case grommet securely.

LEFT

LEFT

TRIM TAB BOLT

TRIM TAB

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

RIGHT

RIGHT

TRIM TAB BOLT

TRIM TAB

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

Adjust the trim tab in small increments, and retest steering effort with the boat evenly loaded and running at cruising speed.

83

08/08/04 18:51:14 31ZY9600_085



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 )

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

ENGINE COVER REMOVAL

AND INSTALLATION

ENGINE

COVER

LATCHES

(front/rear)


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

For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the outboard motor.

UNLATCH

FIX

The engine cover latches fasten the engine cover to the outboard motor.

To remove the engine cover, unlatch both front and rear latches, then lift the engine cover off the outboard motor.

To install the engine cover, place the cover on the outboard motor, then latch both front and rear latches securely.

84

08/08/04 18:51:26 31ZY9600_086


Engine Oil Level Check

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

1.

Unlock and remove the engine

cover (p.

84 ).

2.

Remove the dipstick and wipe it clean.

OIL FILLER CAP

Rid of the alternator cover

Oil filler cap removal (Unlock):

1)

2)

Turn the oil filler cap 90° counterclockwise so the lug of the 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 horizontally.

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

UPPER

LIMIT

4.

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

on p.

88 .

3.


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

LOWER

LIMIT

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

5.

Install the oil filler cap and tighten it securely. Do not overtighten.

6.

Install and lock the engine cover.

85

08/08/04 18:51:34 31ZY9600_087


Engine Oil Change

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

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

1.


cover (p.

84 ).

D R A I N B O L T

GUIDE

SEALING WASHER

Improper disposal of engine oil can be harmf ul to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to a recycling center. Do not throw it in the trash, pour it on the ground or down a drain.

2.

Place a suitable container below the oil drain guide to catch the used oil, and then remove the oil

filler cap (p.

85 ) and the drain bolt.

3.

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

Tighten the drain bolt securely.

86

08/08/04 18:51:44 31ZY9600_088

4.

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

limit mark on the dipstick (p.

85 )

with the recommended oil.

Engine oil refill capacity:

Without oil filter change:

4.4 US qt (4.2 L)

With oil filter change:

4.6 US qt (4.4 L)

5.

Install the oil filler cap and tighten

it securely (p.

85 ).

6.

Install and lock the engine cover.


Oil Filter Change

1.

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

Change on p.

86 ).

2.

Tilt the outboard motor, and place a suitable container below the oil drain guide to catch the used oil.

3.

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

FILTER WRENCH, 64 mm

OIL FILTER

OIL DRAIN GUIDE

RUBBER SEAL

87

08/08/04 18:51:55 31ZY9600_089


4.

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

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

Using the wrong f ilter, or a non-

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

5.

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

OIL FILTER TIGHTENING

TORQUE:

9 lbf·ft (12 N·m , 1.2 kgf·m)

6.

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

7.

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

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

8.

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

Stop the engine, and check the oil

level as described on page 85 . If

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

Engine Oil Recommendations

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

4-stroke automotive detergent oil.

SAE Viscosity Grade

AMBIENT TEMPERATURE

SAE 10W-30 is recommended for general use.

Honda recommends that you use API service category SG, SH or SJ oil with the ‘‘starburst’’ certification mark. The SAE oil viscosity and service category are in the API label on the oil container.

Suggested oil:

Honda 10W-30 FC-W TM outboard motor oil is suggested for general use.

88

08/08/04 18:52:04 31ZY9600_090


Spark Plug Service

RECOMMENDED SPARK PLUGS:

IZFR6K-11E (NGK)

Incorrect spark plugs can 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.

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.

1.

Disconnect the battery negative

( − ) terminal.

2.


cover (p.

84 ).

6 × 20 mm

FLANGE SH BOLT

PLUG MAINTENANCE COVER

3.

Remove the 6 × 20 mm flange

SH bolt and remove the plug maintenance cover.

89

08/08/04 18:52:12 31ZY9600_091


BOX WRENCH

CONNECTOR

LOCK TAB

IGNITION

COIL

0.039

(1.0

−

− 0.051 in

1.3 mm)

SEALING WASHER

INSULATOR

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.

PLUG WRENCH

5.

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

Phillips /flat-tip screwdrivers

(accessories).

6.

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

7.

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

The gap should be 0.039

− 0.051

inches (1.0

− 1.3 mm). If the gap is out of the specification, replace the plug with a new one. Never try to readjust the gap.

90

08/08/04 18:52:20 31ZY9600_092


8.

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

10.

Install the ignition coil. Reinstall the bolt.

9.

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

11.

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

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

12.

Repeat this procedure for the other three spark plugs.

13.

Reinstall the covers.

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

Loose spark plugs can overheat and damage the engine.

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

91

08/08/04 18:52:31 31ZY9600_093


Lubrication Points

Apply Honda Marine waterproof grease to the parts shown below:

Lubrication interval:

After the first 20 hours or 1 month, then every 100 hours or 6 months (refer to

the maintenance schedule on page 81 ).

THROTTLE ARM/

LINK/PIVOT/PLATE

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

THROTTLE ROD/LINK

TILLER HANDLE

(LHT type)

TILT BRACKET

TILT SHAFT

PROPELLER SHAFT SWIVEL CASE THRUST RECEIVER

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

92

08/08/04 18:52:38 31ZY9600_094


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

93

08/08/04 18:52:49 31ZY9600_095


REFUELING

Portable Fuel Tank


FUEL TANK CAPACITY:

6.6 US gal (25 L)

Check the fuel gauge and refill the tank when necessary.

Remove the fuel tank from the boat for refueling.

VENT KNOB

C L O S E

O P E N

FUEL GAUGE

SAFE FILL LEVEL

FUEL FILLER CAP

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

94

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

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

Using the fuel tank mounted in the boat.

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

Fuel can damage paint and plastic.

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

08/08/04 18:52:59 31ZY9600_096







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

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


FUEL RECOMMENDATIONS

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

Your outboard motor is certified to operate on unleaded gasoline.

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

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

Avoid getting dirt or water in the fuel tank.

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

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

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

95

08/08/04 18:53:08 31ZY9600_097


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

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

STORAGE chapter (p.

107 ) for

additional information regarding fuel deterioration.

Water Separator Inspection and

Service

WATER SEPARATOR

Water separator is located near the engine cover latch on 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 cleaning.






1.

Remove the engine cover (p.

84 ).

2.

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

Marine dealer.

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08/08/04 18:53:16 31ZY9600_098

HOSE CLIPS

(commercially available)

WATER

SEPARATOR

WATER

SEPARATOR

BRACKET


WATER

SEPARATOR

HARNESS

CLIP

WATER LEVEL SENSOR

2P CONNECTOR

CLIP C

FUEL HOSES

3.

Pinch the fuel hoses with hose clips to prevent fuel leakage.

SUSPENSION STRAP

4.

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

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

5.

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

2P connector.

6.

Disconnect the fuel hoses from the water separator.

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08/08/04 18:53:26 31ZY9600_099


BODY

BAFFLE

PLATE

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.

POSITIONING

BAND

HARNESS

CLIP

WATER LEVEL

SENSOR 2P

CONNECTOR

SCREW (3)

WATER

SEPARATOR

CUP

SUSPENSION

STRAP

7.

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

8.

Thoroughly clean the water separator cup.

9.

Reassemble the water separator body, baffle plate, O-ring and the cup.

TIGHTENING TORQUE:

2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

98

WATER

SEPARATOR

FLAT PART ON BACK

OF SUSPENSION

JOINT

CLIP C POSITIONING

BAND

10.

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

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

11.

Reinstall the water separator in the reverse order of removal.

08/08/04 18:53:35 31ZY9600_100


12.

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

If the buzzer sounds or excessive water or sediment accumulation are found in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

Fuel Filter Inspection and

Replacement

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

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






99

08/08/04 18:53:44 31ZY9600_101


HOSE CLIPS


FUEL FILTER

STRAINER

BRACKET

FUEL FILTER

(inside strainer cup)

1.

Remove the engine cover (see

page 84 ).

2.

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

HOSE

FUEL FILTER FUEL HOSE

3.

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

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


4.

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

5.

Disconnect the fuel hoses from the fuel filter.

100

08/08/04 18:53:50 31ZY9600_102

FUEL INTAKE

SIDE JOINT

EDGE AT

THE BASE

OF JOINT

FUEL FILTER

(inside strainer cup)

ALIGNMENT

MARK ON THE

SUSPENSION


6.

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

Assemble the fuel filter 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.


7.

Prime the engine using the priming

bulb (refer to page 51 ). Check for

fuel leaks.

Repair any fuel leaks if necessary.

If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

101

08/08/04 18:54:02 31ZY9600_103


Portable Fuel Tank and Tank

Filter Cleaning


Fuel Tank

FUEL HOSE

Fuel Tank Filter

FUEL FILTER JOINT

(Fuel Hose Connector)






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

O-RING

FUEL TANK

FILTER

1.

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

2.

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

3.

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

102

08/08/04 18:54:11 31ZY9600_104

Anode Replacement

ANODE

(each side)

ANODE

(stern bracket)

The anodes are located on each side of the gear case and on the stern bracket. They are made of a sacrificial material that helps to protect the outboard motor from corrosion.

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


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

Propeller Replacement

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

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

Operating the outboard motor at higher altitudes will reduce available power. This may require decreasing the propeller pitch to maintain correct engine RPM.

Removal

1.

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

2.

Inspect the propeller shaft for any fishing line or debris.

103

08/08/04 18:54:23 31ZY9600_105


Installation

1.

Apply marine grade grease to the propeller shaft.

2.

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

3.

Install the propeller.

4.

Install the washer.

5.

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

6.

Tighten the castle nut using torque wrench.

CASTLE NUT TIGHTENING

TORQUE:

0.7 lbf·ft (1 N·m, 0.1 kgf·m)

7.

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

104 cotter pin hole.

TIGHTENING TORQUE LIMIT:

33 lbf·ft (44 N·m, 4.5 kgf·m)

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

8.

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

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

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

MARINE GREASE

PROPELLER (optional equipment)

THRUST WASHER

18.5 mm

WASHER

COTTER PIN

CASTLE NUT

COTTER PIN

08/08/04 18:54:32 31ZY9600_106

STORAGE PREPARATION

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

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

Cleaning and Flushing

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

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

Corrosion Inhibitor, or equivalent.

Lubricate controls with a silicone spray lubricant.

Cleaning

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

HO2 SENSOR

Do not apply water or corrosion inhibitor directly to the electrical components under the engine cover, such as the HO2 sensor. If water or corrosion inhibitor penetrates these components, they may be damaged.

Bef ore applying a corrosion inhibitor, cover the HO2 sensor with a protective material to prevent damage.

STORAGE

Flushing With a Garden Hose

(commercially available)

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

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

105

08/08/04 18:54:39 31ZY9600_107

STORAGE

FLUSH PORT

CONNECTOR

FLUSH PORT

CONNECTOR

GARDEN HOSE

FLUSH PORT

CONNECTOR

1.

Disconnect the flush port connector.

106

GARDEN HOSE JOINT

(Commercially available)

2.

Screw the flush port connector onto the garden hose.

EXHAUST PORT

3.

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

4.

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

08/08/04 18:54:50 31ZY9600_108

STORAGE

Fuel

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

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

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

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

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

Adding a Fuel Stabilizer

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

1.

Drain the vapor separator before adding fuel stabilizer.

2.

Add fuel stabilizer following the manufacturer’s instructions.

3.

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

4.

Turn the engine OFF.

Draining the Fuel System

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

INTAKE MANIFOLD DRAIN TUBE

DRAIN SCREW VAPOR SEPARATOR

107

08/08/04 18:54:59 31ZY9600_109

STORAGE

1.

Remove the engine cover (p.

84 ).

2.

Release the drain tube from the projection of the intake manifold and set the end of the tube toward the outside of the engine undercase.

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

3.

Loosen the vapor separator drain screw.






4.

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

5.

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

6.

Secure the drain tube to the projection of the intake manifold.

7.

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

108

08/08/04 18:55:11 31ZY9600_110

Engine Oil

1.

Change the engine oil and the oil

filter (p.

86 − 88 ).

2.

Remove the spark plugs (p.

89 ),

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

3.

Pour a teaspoon (p.

123 ) (5

− 10 cylinder.

4.

Rotate the engine a few revolutions to distribute the oil in the cylinders.

5.

Reinstall the spark plugs (p.

91 ).

HOISTING THE OUTBOARD

MOTOR

HOIST

HOOKS

ENGINE

HANGERS

STORAGE

4.

After the outboard motor is placed in storage and disconnected from the hoist, install the engine cover.

STORAGE PRECAUTIONS

Select a well-ventilated storage area.

If possible, avoid storage areas with high humidity.

If storing a container of gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark producing electric motor, or where power tools are operated.

1.


cover (p.

84 ).

2.

Attach the hoist hooks to the engine hangers.

3.

Disconnect the outboard motor from the boat, hoist the outboard motor, and move it to the storage area.

109

08/08/04 18:55:19 31ZY9600_111

STORAGE

OUTBOARD MOTOR STAND

If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a commercially available stand.

PROTECTOR

(Port side turned down as shown.)

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

the vapor separator (p.

107 ), and

drain the engine oil (p.

86 ), before

removing the outboard motor from the boat.

Rest the motor on a cushion of protective material.

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

REMOVAL FROM STORAGE

Check your outboard motor as described in the BEFORE

OPERATION chapter of this manual.

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

This is normal.

110

08/08/04 18:55:26 31ZY9600_112

WITH OUTBOARD MOTOR

INSTALLED ON BOAT

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


Use a motor support bar to prevent the outboard motor from moving while trailering the boat. Refer to the manufacturer’s instructions for using a motor support bar.

TRANSPORTING

WITH OUTBOARD MOTOR

REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position

shown on p.

109 and 110 .

MOTOR SUPPORT BAR



Tighten the steering friction knob to prevent the outboard motor from moving while trailering the boat.

111

08/08/04 18:55:34 31ZY9600_113

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

1.

Check emergency stop switch clip.

2.

Check control positions.

Possible Cause

Clip not inserted in emergency stop switch.

Gearshift lever or control lever not in neutral position.

Fast idle lever raised (side-mount type).

Correction

Insert clip in emergency stop switch.

Shift to neutral.

Leave fast idle lever OFF (p.

56 ).

112

08/08/04 18:55:43 31ZY9600_114


(continued)

3.

Check fuel.


Possible Cause

Out of fuel.

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

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

Correction

Refuel (p.

94 ).

Squeeze priming bulb (p.

51 ).

Replace fuel filters (p.

99 ).

Drain fuel tank and vapor

separator (p.

107 ). Refill with

fresh gasoline (p.

94 ).

113

08/08/04 18:55:56 31ZY9600_115



(continued)

4.

Check battery.

Possible Cause

7.

Use starting procedure (p.

52 ,

,

,

); if engine still will

not start, then take outboard motor to an authorized Honda

Marine dealer, or refer to the shop manual.

Battery connections loose or corroded.

5.

Check fuses.

Battery discharged.

Fuse(s) blown.

6.

Remove and inspect spark plugs.

Spark plugs faulty, fouled or improperly gapped.

Spark plugs wet with fuel (flooded engine).

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

Correction

Clean and tighten battery connections.

Recharge battery.

Replace fuse(s) (p.

117 ).

Replace spark plugs (p.

89 ).

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

Replace or repair faulty components as necessary.

114

08/08/04 18:56:05 31ZY9600_116


HARD STARTING OR STALLS

AFTER STARTING

1.

Check control positions.

2.

Check fuel.

Possible Cause

Fast idle lever raised (side-mount type).

Fuel hose not primed.

Fuel filter or fuel tank clogged.

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

Correction

Leave fast idle lever OFF (p.

56 ).

Squeeze priming bulb (p.

51 ).

Replace fuel filters (p.

99 ).

Drain fuel tank and vapor

separator (p.

107 ). Refill with

fresh gasoline (p.

94 ).

115

08/08/04 18:56:17 31ZY9600_117


HARD STARTING OR STALLS

AFTER STARTING

(continued)

3.

Remove and inspect spark plugs.

Possible Cause

4.

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

Spark plugs faulty, fouled or improperly gapped.

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

Correction

Replace spark plugs (p.

89 ).


ENGINE OVERHEATS

1.

Check water intake screens.

2.

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

Possible Cause

Water intake screens clogged.

Faulty thermostat or water pump.

Correction

Clean water intake screens.


116

08/08/04 18:56:28 31ZY9600_118


Fuse Replacement

3.

Remove the electrical parts cover.

FUSES

Electric Starter Will Not

Operate

The 10A, 15A, and 30A main fuses protect the electric starter relay and related circuits.

The 10A main fuse protects the ignition switch and related circuits. If this fuse blows, the engine will not start or run, and the power trim/tilt switch will not activate the trim/tilt mechanism.

Battery Will Not Charge

A 70A ACG fuse protects the alternator circuit. If the ACG fuse blows, the engine will not charge the

battery. Refer to p.

118 .

Disconnect the battery cable at the battery negative ( − ) terminal bef ore replacing the f use.

Failure to do so may cause a short circuit.

Main Fuse

1.

Stop the engine and disconnect the battery cable.

2.

Remove the engine cover.

LOCK TABS

ELECTRICAL PARTS COVER

4.

Remove the fuse case lid.

FUSES

(10 A, 15 A, 30 A)

FUSE CASE LID

SPARE FUSES

(10 A, 15 A, 30 A)

117

08/08/04 18:56:40 31ZY9600_119


FUSE PULLER

5.

Use the fuse puller from the tool kit to remove the fuses. If a fuse is blown, install a replacement fuse of the same specified rating. The outboard motor is supplied with spare fuses in the fuse holder.

MAIN FUSE RATINGS:

10A, 15A, 30A

6.

Reinstall the fuse case lid, electrical parts cover, and the engine cover.

7.

Reconnect the battery.

ACG Fuse

‘‘70A’’MARK SPARE FUSE (70A)

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

If a blown fuse is found, try to determine and correct the electrical problem that caused the blown fuse.

An uncorrected electrical problem may cause the fuse to blow again.

If fuses continue to blow, take the outboard motor to an authorized

Honda Marine dealer for inspection and service, or refer to the shop manual.

FUSE CASE

LID

ACG FUSE (70A)

1.

Stop the engine and disconnect the battery cable.

2.

Remove the engine cover.

3.

Remove the electrical parts cover.

4.

Remove the fuse case lid.

5.

Remove the old fuse by removing two 5 mm screws.

118

08/08/04 18:56:52 31ZY9600_120


6.

Install a new fuse with the ‘‘70A’’ mark downward.

ACG FUSE RATING: 70A

7.

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

8.

Be sure the fuse case lid is securely locked.

9.

Reinstall the electrical parts cover and engine cover.

10.

Reconnect the battery.

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 is set as a spare fuse on the reverse side of the fuse case lid, set the fuse so that you can see the ‘‘70A’’ mark on it.

OIL PRESSURE INDICATOR

GOES OFF AND ENGINE

SPEED IS LIMITED


(GREEN)




Side-Mount Type

(GREEN)

BUZZER


(GREEN)

BUZZER

119

08/08/04 18:57:01 31ZY9600_121



Normal

Abnormal

If oil pressure becomes low, the oil pressure indicator will go off, and the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically.

The oil pressure indicator is also equipped with a buzzer that sounds when the oil pressure indicator goes off.

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

120

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

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

(p.

85 ), and add oil if needed.

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

OK, the oil pressure indicator should come on within 30 seconds, and the engine will respond normally to throttle control lever operation.

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

OVERHEAT INDICATOR

COMES ON AND ENGINE

SPEED IS LIMITED


(RED)


08/08/04 18:57:13 31ZY9600_122



Side-Mount Type

(RED)



Normal

Abnormal

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

COOLING SYSTEM INDICATOR

BUZZER


(RED)

BUZZER

If the engine overheats, the overheat indicator will come on, and the engine will stop in 20 seconds after the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically.

All types are equipped with a buzzer that sounds when the overheat indicator comes on.

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

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

121

08/08/04 18:57:23 31ZY9600_123


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

30 seconds. If the cooling system is

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

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

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

WATER SEPARATOR

BUZZER SOUNDS

WATER SEPARATOR

INDICATOR


Normal

Abnormal

WATER SEPARATOR

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

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

the instructions on page 96 , or

consult with an authorized Honda

Marine dealer.

When the water separator indicator blinks:

Check the water separator for water contamination. If water has accumulated, stop the engine, and clean the water separator following

the instructions on page 96 , or

consult with an authorized Honda

Marine dealer.

122

08/08/04 18:57:33 31ZY9600_124


SUBMERGED MOTOR

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

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

1.

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

2.

Drain the vapor separator as

described on p.

107 .

3.

Change the engine oil and oil filter

as described on p.

86 − 88 . If

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

4.

Remove the spark plugs (p.

89 ).

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

5.

Pour a teaspoon (p.

109 ) of engine

oil into each spark plug hole to lubricate the inside of the cylinders.

Reinstall the spark plugs.

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

6.

Attempt to start the engine (be sure the water level is at least 2 inches above the antiventilation plate).

If you are changing the oil filter while the outboard motor is out of the water, use commercially available

Ear-muffs and water hose to supply water.

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

123

08/08/04 18:57:38 31ZY9600_125


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

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

7.

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

Honda Marine dealer for inspection and service.

124

08/08/04 18:57:45 31ZY9600_126

TECHNICAL AND CONSUMER INFORMATION

TECHNICAL INFORMATION

Serial Number Locations

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

warranty inquiries (p.

134 ).

PRODUCT

IDENTIFICATION

NUMBER

ENGINE SERIAL NUMBER

RIGHT STERN BRACKET

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

Product identification number:

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

Engine serial number:

Date of purchase:

125

08/08/04 18:57:55 31ZY9600_127


Battery

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

Minimum Requirements

12V − 65Ah/20HR

(CCA582A)

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

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

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

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

This voltage drop may cause the buzzer to sound momentarily when

126

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

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

Wash your hands after handling.

Emission Control System

Information

Source of Emissions

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

Honda utilizes various systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

Ignition Timing Control System

The system constantly adjusts the ignition timing, reducing the amount of HC, CO and NOx produced.

08/08/04 18:58:02 31ZY9600_128

PGM-FI System

The PGM-FI system uses sequential multiport fuel injection. It has two subsystems: Engine Control, and

Fuel Control. The Engine Control

Module (ECM) uses various sensors to determine how much air is going into the engine. It then controls how much fuel to inject under all operating conditions.


The U.S. and Calif ornia Clean

Air Acts

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

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

Honda engine within the emission standards.

Tampering and Altering

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

Among those acts that constitute tampering are:

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

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

127

08/08/04 18:58:11 31ZY9600_129


Problems That May Af f ect

Emissions

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

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

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

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

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

Maintenance

Follow the maintenance schedule on

p.

81 . Remember that this schedule

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

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Star Label

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

Air Resources Board.


The Star Label means Cleaner Marine Engine

This engine has been certified as a:

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water for healthier lifestyle and environment.

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

Longer Emission Warranty protects consumer for worry-free operation.

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One Star

Low

Emission

Two Stars

Very Low

Emission

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

Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

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

Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than

One Star-Low Emission engines.

Three Stars

Ultra Low

Emission

Four Stars

Super Ultra

Low Emission

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

Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003-2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low Emission engines.

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

Sterndrive and Inboard marine engine 2009 exhaust emission standards.

Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star-Low Emission engines.

Cleaner Watercraft - Get the Facts

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

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Specifications

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

[weight] ＊

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Steering control system

Starter system

Ignition system

Lubrication system

377 lbs (171 kg)

BF75D

BBAJ

LHT LRT

35.6 in (904 mm)

25.4 in (646 mm)

29.4 in (746 mm)

17.7 in (449 mm)

61.7 in (1,566 mm)

21.1 in (537 mm)

364 lbs (165 kg)

55.9 kW (75 HP)

5,000 − 6,000 rpm

4 stroke OHC in-line 4-cylinder

91.3 cu-in (1,497 cm )

0.039

− 0.051 in (1.0

− 1.3 mm)

Motor-mounted,

Tiller handle remote control

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine: API standard (SG, SH, SJ) SAE

10W-30

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

Engine: 4.4 US qt (4.2 L) without oil filter change

4.6 US qt (4.4 L) with oil filter change

Gear case: 1.00 US qt (0.95 L)

ULTRA · LOW EMISSION

12V − 35A

Water cooling with thermostat

Water exhaust

IZFR6K-11E (NGK)

Low pressure side: mechanical type

High pressure side: electrical type

Unleaded gasoline

(86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

− 4° to 16° (when Transom angle at 12°)

68° (when Transom angle at 12°)

8°, 12°, 16°, 20°, 24°

＊ Without battery cable, with propeller

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

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Specifications

MODEL

Description code

Type

Overall length

Overall width

Overall height

Transom height

(when transom angle at 12°)

Dry mass

[weight] ＊

Rated power

Full throttle range

Engine type

Displacement

Spark plug gap

Steering control system

Starter system

Ignition system

Lubrication system

LHT

35.6 in

(904 mm)

25.4 in

(646 mm)

61.7 in

(1,566 mm)

21.1 in

(537 mm)

LRT XRT

29.4 in

(746 mm)

17.7 in

(449 mm)

66.7 in

(1,693 mm)

26.1 in

(664 mm)

379 lbs

(172 kg)

BF90D

BBCJ

366 lbs

(166 kg)

67.1 kW (90 HP)

5,300 − 6,300 rpm

379 lbs

(172 kg)

4 stroke OHC VTEC in-line 4-cylinder

91.3 cu-in (1,497 cm )

0.039

− 0.051 in (1.0

− 1.3 mm)

Motor-mounted,

Tiller handle remote control

Electric starter

Full transistor battery

Trochoid pump pressure lubrication

Specified oil

Oil capacity

CARB star label

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Gear change

Steering angle

Trim angle

Tilt up angle

Transom angle

Engine: API standard (SG, SH, SJ)

SAE 10W-30

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

Engine: 4.4 US qt (4.2 L) without oil filter change

4.6 US qt (4.4 L) with oil filter change

Gear case: 1.00 US qt (0.95 L)

ULTRA · LOW EMISSION

12V − 35A

Water cooling with thermostat

Water exhaust

IZFR6K-11E (NGK)

Low pressure side: mechanical type

High pressure side: electrical type

Unleaded gasoline

(86 pump octane or higher)

Forward-Neutral-Reverse (dog type)

30° right and left

− 4° to 16° (when Transom angle at 12°)

68° (when Transom angle at 12°)

8°, 12°, 16°, 20°, 24°

＊ Without battery cable, with propeller

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

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BF75D/BF90D Tune up

Spark plug gap (do not adjust)

Idle speed

Valve clearance (cold)

Other specifications


Intake:

0.039

− 0.051 in (1.0

− 1.3 mm)

750 ± 50 rpm

Exhaust:

0.17

± 0.02 mm

0.28

± 0.02 mm

No other adjustment is needed

See page 90

See shop manual

See shop manual

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CONSUMER INFORMATION

Honda Publications

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

Shop Manual

This manual covers complete maintenance and overhaul procedures.

It is intended to be used by a skilled technician.

Available through your Honda

Marine dealer or through Helm Inc.

at

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

and click on OWNERS.

Parts Catalog

This manual provides complete, illustrated parts lists.

The catalog is available through your

Honda Marine dealer.

134

Accessory Catalog

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

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

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

Customer Service Information

If you need to contact American

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

Contacting Honda

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

Manual can be answered by your

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

American Honda Motor Co., Inc.

Marine Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, GA 30005-8847

Telephone (770) 497 − 6400

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

Zone)

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

08/08/04 19:00:10 31ZY9600_136

Please include the following information in your communication:

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

Model and complete serial number

Date of purchase

Name and location of selling dealer

Name and location of servicing dealer (if different)

A detailed description of your concerns


Warranty Coverage

Your new Honda is covered by the following warranties:

Distributor’s Limited Warranty

Emission Control System

Warranty

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

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

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

United States, Puerto Rico, or the

U.S. Virgin Islands.

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

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

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

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08/08/04 19:00:16 31ZY9600_137


Warranty Service

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

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

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

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

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

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

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

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

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

08/08/04 19:00:27 31ZY9600_138


Distributor’s Limited Warranty

This warranty is limited to Honda Outboard Motors distributed by American Honda Motor Co., Inc., Power Equipment

Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.

Products Covered by Warranty:

All Models: Model Year 2000 and Newer ＊

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

NONCOMMERCIAL/ COMMERCIAL/RENTAL STATE/LOCAL/FEDERAL

NONRENTAL

36 months 12 months

GOVERNMENT

24 months

Models BF115/BF130: All Model Years

＊ 36 months 12 months 24 months

Models BF2 − BF90: Model Year 1999 and Earlier ＊

24 months 12 months

All Models purchased after July 1, 2008 60 months 12 months

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

24 months

24 months

To Qualify for This Warranty:

The Honda Outboard Motor must be purchased from

American Honda or a dealer authorized by American

Honda to sell Honda Outboard Motors in the United

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

What American Honda Will Repair or Replace Under

Warranty:

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

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

To Obtain Warranty Service:

You must take your Honda Outboard Motor and proof of the original purchase date, at your expense, to any dealer who is authorized to service Honda Outboard Motors in the United States, Puerto Rico, or the U.S. Virgin Islands, during the dealer’s normal business hours.

If you are unable to obtain warranty service, or are dissatisfied with the warranty service you receive, take the following steps: First, contact the owner of the dealership involved; normally this should resolve the

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08/08/04 19:00:39 31ZY9600_139


problem. However, if you should require further assistance, write or call the Honda Marine Customer

Relations. Please see Contacting Honda

page 134 .

Exclusions:

This warranty does not extend to the following:

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

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

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

Manual)

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

Normal wear and tear

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

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

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

Incorporation of unsuitable attachments or parts

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

138

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

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

Growth of marine organisms on motor surfaces, external or internal

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

’’

Disclaimer of consequential damage and limitation of implied warranties:

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

08/08/04 19:00:49 31ZY9600_140


Accessories and Replacement Parts

This warranty is limited to Honda Power Equipment parts,accessories and apparel when distributed by American Honda

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

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

Non Commercial Commercial/Rental Local/State/Federal

Government

Accessories

Replacement Parts

12 months

6 months

3 months

3 months

3 months

3 months

To Qualify for This Warranty:

1.

The accessories or replacement parts must be purchased from American Honda, or a dealer,

2.

distributor or distributor’s dealer authorized by

American Honda to sell those products in the United

States, Puerto Rico, and the U.S. Virgin Islands.

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

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

What American Honda Will Repair or Replace Under

Warranty:

American Honda will repair or replace, at its option, any marine product accessories or replacement parts that are proven to be defective in material or workmanship under normal use during the applicable warranty time period.

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

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

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To Obtain Warranty Service:

You must take the Honda Outboard Motor product accessory or replacement part or the outboard motor or boat on which the accessory or replacement part is installed, and proof of purchase, at your expense, to any

Honda Marine authorized service facility or dealer in the

United States, Puerto Rico, or the U.S. Virgin Islands, during normal business hours.

Exclusions:

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

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

Disclaimer of consequential damage and limitation of implied warranties:

American Honda disclaims any responsibility for loss of time or use of the outboard motor, or the boat on which the product is installed, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written warranty. Some states do not allow limitations on

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

08/08/04 19:01:03 31ZY9600_142


Emission Control System Warranty

Your new Honda outboard engine complies with both the

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

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

YOUR WARRANTY RIGHTS AND OBLIGATION

California

The California Air Resources Board and American

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

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

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

Other States

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

EPA Emission Standard for spark ignited marine engines.

All States

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

American Honda Motor Co., Inc. will repair your outboard engine at no cost to you including diagnosis, parts and labor.

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

MANUFACTURER’S EMISSION CONTROL

SYSTEM WARRANTY COVERAGE:

The 2001 and later outboard engines are warranted for a minimum of four years or 250 hours of operation, whichever comes first, or the length of Honda Marine

Distributor’s Limited warranty, whichever is longer.

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

Motor Co., Inc.

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08/08/04 19:01:08 31ZY9600_143


OWNER’S WARRANTY RESPONSIBILITY:

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

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

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

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

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

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

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

Motor Co., Inc., Marine Division Customer Relations

Office. Please see

Contacting Honda page 134.

WARRANTY COVERAGE:

Honda outboard engines manufactured after June 1, 2001 are covered by this warranty for a minimum of four years or 250 operating hours, whichever comes first, or the length of the Honda Marine Distributor’s Limited warranty, whichever is longer from the date of delivery to the retail purchaser. This warranty is transferred to each subsequent purchaser for the duration of the warranty period.

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

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

144. Normal maintenance items, such as spark plugs and

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

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

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

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

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08/08/04 19:01:14 31ZY9600_144


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

TO OBTAIN WARRANTY SERVICE:

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

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

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

Customer Relations Office of American Honda Motor

Co., Inc.

EXCLUSIONS:

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

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

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

DISCLAIMER OF CONSEQUENTIAL DAMAGE

AND LIMITATION OF IMPLIED WARRANTIES:

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

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EMISSION CONTROL SYSTEM WARRANTY PARTS:

SYSTEMS COVERED BY THIS

WARRANTY:

Fuel Metering

Air Induction

Ignition

PARTS DESCRIPTION

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

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

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

Lubrication system

Crankcase Emission Control

Exhaust

Valve Control System

Oil pump and internal parts

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

Exhaust manifold and Exhaust valves

Rocker arm oil control valve

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

＊

Covered up to the first required replacement only. See the Maintenance Schedule on page 81.

144

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INDEX

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

. 38

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

. 44

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

. 103

ARE YOU READY TO GET UNDERWAY?

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

. 45

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

Will Not Charge ......................................................

. 126

. 117

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

. 45

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

. 48

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

. 33

COMPONENT AND CONTROL LOCATIONS

CONSUMER INFORMATION

........

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

. 11

. 134

CONTROL AND FEATURE IDENTIFICATION

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

. 10

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

. 19

CONTROLS AND FEATURES

CRUISING

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

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

. 41

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

. 10

. 73

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

. 134

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

. 37

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

. 36

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

. 137

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

. 117

EMERGENCY

STARTER ROPE ......................................................

. 80

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

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

. 63

. 126

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

. 141

Engine

Cover

Oil

Latch (front/rear) ...................................................

. 35

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

. 84

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

. 86

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

. 87

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

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

. 85

. 88

OVERHEATS .........................................................

. 116

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

. 112

145

08/08/04 19:01:29 31ZY9600_147

INDEX

Fast Idle Button

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

. 28

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

. 32

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

. 24

Fuel

Filler Cap Vent Knob (optional equipment) .............

. 43

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

. 99

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

. 37

HOSE CONNECTIONS

PRIMING

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

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

. 50

. 51

Priming Bulb (optional equipment) ..........................

. 43

RECOMMENDATIONS

Fuse Replacement

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

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

. 95

. 117

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

. 117

Gearshift Lever (LHT Type) .........................................

. 21

Gearshift/Throttle Control Lever

(LRT and XRT Types)

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

. 27

Side-Mount Type

Top-Mount Type

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

. 23

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

. 30

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

. 69

HARD STARTING OR STALLS AFTER

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

. 115

HOISTING THE OUTBOARD MOTOR

Honda Publications

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

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

. 109

. 134

146

Ignition Switch

LHT Type ..................................................................

. 19

LRT and XRT Types

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

. 25

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

. 22

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

. 29

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

. 7

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

. 38

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

. 36

IS YOUR OUTBOARD MOTOR

READY TO GO?

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

. 45

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

. 92

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

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

. 79

. 81

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

. 34, 84

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

. 76

08/08/04 19:01:32 31ZY9600_148

INDEX

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

. 39

OIL PRESSURE INDICATOR GOES OFF AND

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

. 119

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

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

. 48

. 42

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

. 7

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

OVERHEAT INDICATOR COMES ON AND

. 40

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

. 120

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

. 42 and Tank Filter Cleaning (optional equipment) ......

. 102

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

. 34

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

. 33

Programmed Fuel Injection (PGM-FI) Indicator ..........

. 38

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

. 103

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

. 94

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

. 110

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

. 48

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

. 9

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

. 125

SERVICING YOUR OUTBOARD MOTOR

SHALLOW WATER OPERATION

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

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

. 78

. 75

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

. 89

Specifications

Star Label

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

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

. 131

. 129

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

. 52

LHT Type ..................................................................

. 52

LRT and XRT Types

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

. 58

Side-Mount Type

Top-Mount Type

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

. 55

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

. 60

Steering Friction Knob (LHT Type) .............................

. 21

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

. 72

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

. 66

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

. 66

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

. 67

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

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

. 105

. 109

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

. 105

Cleaning and Flushing

Engine oil

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

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

. 105

. 109

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

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

. 107

. 123

Switch Clip and Emergency Stop Switch

LHT Type ..................................................................

. 19

LRT and XRT Types

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

. 26

Side-Mount Type

Top-Mount Type

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

. 22

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

. 29

147

08/08/04 19:01:35 31ZY9600_149

INDEX

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

. 36

TECHNICAL AND CONSUMER

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

. 125

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

. 125

THE IMPORTANCE OF MAINTENANCE

Throttle

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

. 78

Friction Adjuster (LHT Type) ...................................

. 21

Grip (LHT Type) .......................................................

. 20

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

. 35

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

. 80

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

WITH OUTBOARD MOTOR INSTALLED

. 111

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

WITH OUTBOARD MOTOR REMOVED

. 111

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

Trim Meter (optional equipment)

. 111

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

. 36

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

. 35

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

. 83

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

. 42

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

. 122

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

. 122

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

. 96

148

Honda BF90D Owner's Manual 151 Pages

Honda BF90D Owner's Manual

INTRODUCTION

INTRODUCTION

A FEW WORDS ABOUT

SAFETY

2

CONTENTS

CONTENTS

CONTENTS

CONTENTS

IMPORTANT SAFETY

INFORMATION

OUTBOARD MOTOR SAFETY

Operator Responsibility

7

OUTBOARD MOTOR SAFETY

Refuel With Care

Carbon Monoxide Hazard

8

SAFETY LABEL LOCATION

OUTBOARD MOTOR SAFETY

9

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

10

CONTROLS AND FEATURES

COMPONENT AND CONTROL LOCATIONS

11

CONTROLS AND FEATURES

CONTROLS AND FEATURES

CONTROLS AND FEATURES

CONTROLS AND FEATURES

Remote Controls (optional equipment)

15

CONTROLS AND FEATURES

Indicator Panel

(standard equipment)

CONTROLS AND FEATURES

Fuel Hose Assembly

(optional equipment)

17

CONTROLS AND FEATURES

Trim Meter

(optional equipment)

Tachometer

(optional equipment)

Digital Speedometer

(optional equipment)

Digital Tachometer

(optional equipment)

18

CONTROLS

LHT Type (tiller handle)

Ignition Switch

CONTROLS AND FEATURES

Emergency Stop Switch Clip and

Emergency Stop Switch

19

CONTROLS AND FEATURES

Throttle Grip

Throttle Friction Adjuster

CONTROLS AND FEATURES

Gearshif t Lever

Steering Friction Knob

CONTROLS AND FEATURES

LRT and XRT Types

(remote control)

Side-Mount Type

Ignition Switch

Emergency Stop Switch Clip and

Emergency Stop Switch

22

CONTROLS AND FEATURES

Gearshif t/Throttle Control

Lever

CONTROLS AND FEATURES

Fast Idle Lever

Panel-Mount Type

Ignition Switch