HONDA
02001
Honda
Motor Co.,
Ltd.
-All
Rights Reserved
2002
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects,
or
other reproductive harm.
Keep this owner’s manual handy, so you can refer to it at any time. This owner’s
manual is considered a permanent part
of
the outboard motor and should remain with
the outboard motor if resold.
The information and specifications included in this publication were in effect at the
time of approval for printing. Honda Motor
Co.,
Ltd. reserves the right, however, to
discontinue
or change specifications or design at any time without notice and without
incurring any obligation whatever.
No
part
of
this publication may be reproduced
without written permission.
INTRODUCTION
Congratulations on your selection of
a Honda outboard motor. We are
certain you will be pleased with your
purchase of one of the finest
outboard motors on the market.
We want to help you get the best
results from your new outboard
motor and to operate it safely. This
manual contains the information on
how to do that; please read it
carefully.
As you read this manual you will
find information preceded by a
symbol. That information
is intended to help you avoid damage
to your outboard motor, other
property, or the environment.
We suggest you read the warranty
policy to
fully
understand its
coverage and your responsibilities of
ownership. The warranty policy is a
separate document that should have
been given to you by your dealer.
When your outboard motor needs
scheduled maintenance, keep
in
mind
that your Honda marine dealer is
specially trained in servicing Honda
outboard motors. Your Honda marine
dealer is dedicated
to
your
satisfaction and will be pleased to
answer your questions and concerns.
0
2001
Honda Motor Co., Ltd. All
Rights Reserved
1
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 A and one of
three signal words, DANGER, WARNING, or CAUTION.
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
CONTENTS
OUTBOARD MOTOR SAFETY
....................................
7
IMPORTANT SAFETY INFORMATION
.................
7
SAFETY LABEL LOCATIONS
.................................
9
CONTROLS AND FEATURES
................................... 10
CONTROL AND FEATURE IDENTIFICATION
CODES
...................................................................
10
COMPONENT AND CONTROL LOCATIONS
.....
11
CONTROLS
...............................................................
15
Side-Mount Type
Ignition Switch
.......................................................
15
Switch Clip and Emergency Stop Switch
..............
16
GearshifdThrottle Control Lever
...........................
16
Fast Idle Lever
........................................................
I8
Ignition Switch
.......................................................
I8
Switch Clip and Emergency Stop Switch
..............
19
Throttle Button
....................................................... 20
GearshifVThrottle Control Lever
...........................
20
Panel-Mount Type
Top-Mount Type
Ignition Switch
.......................................................
22
Switch Clip and Emergency Stop Switch
..............
22
Fast Idle Button
......................................................
23
GearshifdThrottle Control Lever ........................... 23
Power TridTilt Switch
.........................................
25
Power Tilt Switch
...................................................
26
Manual Relief Valve
..............................................
26
Tilt Lock Lever
......................................................
26
Engine Cover Latch
...............................................
27
Trim Tab
................................................................. 27
INSTRUMENTS
........................................................
27
Trim Meter (optional equipment)
.......................... 27
Tachometer (optional equipment)
..........................
28
Common Controls
3
CONTENTS
INDICATORS
............................................................
28
Alternator (AGC) Indicator
....................................
28
Programmed Fuel Injection (PGM-FI) Indicator
...
28
Oil Pressure Indicator
.............................................
29
Overheating Indicator
............................................
29
Cooling System Indicator
......................................
30
OTHER FEATURES
.................................................
30
Water Contamination Buzzer
.................................
30
Overrev Limiter
......................................................
3
1
Anodes ....................................................................
3
1
Fuel Priming Bulb
..................................................
31
ARE YOU READY TO GET UNDER WAY
?
......
32
BEFORE OPERATION
.................................................
32
IS YOUR OUTBOARD MOTOR
READY TO GO
?
.................................................
32
OPERATION
................................................................. 34
SAFE OPERATING PRECAUTIONS
.....................
34
FUEL PRIMING
........................................................
35
STARTING THE ENGINE ....................................... 36
Side-Mount Type
...................................................
36
Panel-Mount Type
..................................................
39
Top-Mount Type
....................................................
41
STOPPING THE ENGINE
........................................
43
Emergency Engine Stopping
.................................
43
Normal Engine Stopping 44
THROTTLE OPERATION
............................... 45
Side-Mount Type
................................................... 45
Panel-Mount Type
..................................................
46
Top-Mount Type
....................................................
46
STEERING
................................................................
47
CRUISING
.................................................................
48
SHALLOW WATER OPERATION
.........................
50
MOORING. BEACHING. LAUNCHING ................
50
BREAK-IN PROCEDURE
........................................
34
........................................
GEARSHIFTING AND
4
CONTENTS
SERVICING YOUR OUTBOARD MOTOR
...............
52
THE IMPORTANCE OF MAINTENANCE
............
52
MAINTENANCE SAFETY
...................................... 53
MAINTENANCE SCHEDULE
................................ 55
TRIM TAB ADJUSTMENT
.....................................
57
MANUAL RELIEF VALVE
.....................................
58
ENGINE COVER REMOVAL AND
INSTALLATION
................................................... 58
Latch Adjustment
.......................................................
59
Cover Lock Bolt Adjustment
.....................................
59
Engine Oil Level Check
.............................................
60
Engine Oil Change
.....................................................
60
Engine Oil Recommendations
...................................
62
Lubrication Points
...................................................... 63
TOOL
KIT
(optional equipment) ............................... 54
Spark Plug Service
.....................................................
64
FUEL RECOMMENDATIONS
................................
68
Water Separator
..........................................................
71
Anode Replacement
...................................................
73
Propeller Replacement
...............................................
74
STORAGE
..................................................................... 75
STORAGE PREPARATION
....................................
75
Cleaning and Flushing
...........................................
75
Fuel
......................................................................... 77
HOISTING THE OUTBOARD
MOTOR 78
Engine Oil
78
STORAGE PRECAUTIONS
....................................
79
REMOVAL FROM STORAGE
................................
80
Fuel Pump Filter Inspection and Replacement
..........
69
..............................................................
.................
5
CONTENTS
TRANSPORTING
.........................................................
81
INSTALLED ON BOAT
.......................................
81
REMOVED FROM BOAT
...................................
81
TAKING CARE
OF
UNEXPECTED PROBLEMS
.....
82
WITH OUTBOARD MOTOR
WITH OUTBOARD MOTOR
BATTERY WILL NOT CHARGE AND
ELECTRIC STARTER WILL NOT
OPERATE
..........................................................
87
OIL PRESSURE INDICATOR LIGHT GOES OFF
AND ENGINE SPEED
IS
LIMITED .................... 89
OVERHEATING INDICATOR LIGHT COMES
ON AND ENGINE SPEED IS LIMITED
.............
90
SUBMERGED MOTOR
........................................... 91
TECHNICAL AND CONSUMER INFORMATION
...
93
TECHNICAL INFORMATION
................................
93
Serial Number Locations
....................................... 93
Oxygenated Fuels
...................................................
94
Battery
....................................................................
95
Emission Control System Information
..................
96
Star Label
...............................................................
98
Specifications
.......................................................
100
CONSUMER INFORMATION .............................. 103
INDEX
..........................................................................
104
WIRING DIAGRAMS
.........................
Inside Back Cover
6
OUTBOARD
MOTOR
SAFETY
IMPORTANT SAFETY
INFORMATION
Honda BF200NBF225A outboard
motors are designed for use with
boats that have a suitable
manufacturer’s power
recommendation. Other uses can
result in injury to the operator or
damage to the outboard motor and
other property.
Most accidents can be prevented if
you follow all instructions in this
manual and on the outboard motor.
The most common hazards are
discussed below, along with the best
way to protect yourself and others.
Operator Responsibility
It is the operator’s responsibility to
provide theaecessary 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.
0
Always wear a PFD (Personal
Flotation Device) while on the
boat.
0
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
OUTBOARD MOTOR SAFETY
Refuel
With
Care
Gasoline is extremely flammable,
and gasoline vapor can explode.
Refuel outdoors, in a well-
ventilated 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. Avoid inhalation
of exhaust gas. Never run the engine
in a closed garage or confined area.
8
OUTBOARD MOTOR SAFETY
SAFETY LABEL LOCATIONS
I
A
WARNING
I
IPLACE TRANSMISSION IN NEUTRAL BEFORE STARTING.
ID0
NOT OPERATE WITH ENGINE COVER REMOVED.
IBE SURE THE ANTIVENTILATION PLATE
IS
BELOW THE
ID0
NOT SHIFT
TO
REVERSE SUDDENLY AT HIGH
WATER LINE.
SPEED.
1
I
ICHECK OIL LEVEL BEFORE STARTING.
IFLUSH THE SYSTEM THOROUGHLY WITH FRESH WATER
AFTER EACH USE IN SALT WATER.
The labels shown here contain important safety information. Please read them carefully. These labels are considered
permanent parts
of
your outboard motor.
If
a label comes off or becomes hard to read, contact an authorized Honda
Marine servicing dealer for a replacement.
9
CONTROLS AND FEATURES
CONTROL AND FEATURE IDENTIFICATION CODES
Model
BF225A
BFZOOA
Type
XXCA
XXA XCA
XA LA
XXCA
XXA
XCA
XA
LA
20.0
in
(508
mm)
e
Transom Height
25.0
in
(635
mm)
e
e
e
e
30.0
in
(762
nun)
e
e
e
e
Standard Rotating Propeller Shaft
e
e
e
e
e
e
Counterrotating Propeller Shaft
e
e
e
e
e
e
e
e
e
e
Power TrimiTilt
e
e
e
e
Refer
to
this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.
TYPE CODE (example)
Destination
A: America
Rotating direction of propeller shaft
C: Counterrotating propeller shaft
None: Standard rotating propeller shaft
Transom Height
L:
20.0
in
(508
mm),
X:
25.0
in
(635
mm),
XX:
30.0
in
(762
mrn)
1Q
CONTROLS
AND FEATURES
COMPONENT AND CONTROL LOCATIONS
OIL FILLER CAP
(inside engine cover)
J
ENGINE COVER
:
OIL LEVEL DIPSTICK
/ENGINE COVER
\
LATCH
L
STERN
BRACKET
ANODE
I
SPARK PLUG
(under coil)
COOLING SYSTEM
INDICATOR
TILT LOCK
ENGINE OIL
DRAIN BOLT
..
. .
,
(inside cover)
'...
...
FRAME SERIAL
u
I,
FLUSH PLUG
CONNECTOR
GEAR OIL
LEVEL PLUG ANTIVENTILATION
TRIM TAB
GEAR OIL DRAIN
PLUG EXHAUST PORTNVATER
OUTRET PORT
COOLING
\
PROPELLER
WATER
INTAKE PORT
11
CONTROLS AND FEATURES
Remote Controls (optional equipment)
(SIDE-MOUNT REMOTE CONTROL) (PANEL-MOUNT REMOTE CONTROL)
GEARSHIFTmHROTTLE
GEARSHIFTiTHROTTLE
CONTROL LEVER
NEUTRAL CONTROL LEVER
RELEASE
NEUTRAL
OIL PRESSURE
DICATOR LIGHT
SPARE SWITCH CLI
CONTROL LEVER
FRICTION ADJUSTER
LANYARD EMERGENCY
STOP SWITCH
SWITCH CLIP
12
CONTROLS AND FEATURES
(SINGLE TOP-MOUNT REMOTE CONTROL)
GEARSHIFTRHROTTLE
CONTROL LEVER
CONTROL PANEL
(for
PANELD'OP-MOUNT
type)
OIL PRESSURE
INDICATOR LIGHT
INDICATOR LIGl
SWITCH CLIP EMERGENCY
STOP SWITCH
(DUAL TOP-MOUNT REMOTE CONTROL)
GEARSHIFTRHROTTLE
CONTROL LEVERS
POWER TRIM/TILT
SWITCH (RIGHT)
POWER TRIM/TILT
SWITCH (LEFT)
FAST IDLE
BUTTON
IT
13
CONTROLS AND FEATURES
Trim Meter
(optional equipment)
14
CONTROLS AND FEATURES
CONTROLS
Side-Mount Type
Ignition Switch
The ignition switch controls the
ignition system and starter motor.
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the
ON
position when released
from the START position.
The ignition switch can be used to
operate the starter motor only when
the control lever (p.
17
)
is
in
the
N
(neutral) position, and the switch clip
is in the emergency stop switch.
Turning the ignition switch to the
OFF
position stops the engine.
15
CONTROLS AND FEATURES
Switch Clip and Emergency Stop
Switch
EMERGENCY
STOP SWITCH
\
I
”
LANYARD
SWITCH CLIP
SWITCH CLIP
The switch clip must be inserted
in
the emergency stop switch in order
for the engine to start and run. The
lanyard must
be
attached to the
operator’s
PFD
(Personal Flotation
Device) or
worn
around the wrist
as
shown.
When used as described, the
emergency stop switch and lanyard
system stops the engine if the
operator falls away from the controls.
A
spare switch clip
is
stored in
a
slot
in
the control housing (optional
equipment).
SPARE SWITCH CLIP
Gearshift/Throttle Control
Lever
CONTROL LEVER
The gearshiftlthrottle control lever
controls engine speed and selects
F
(forward),
N
(neutral), or
R
(reverse)
gears.
16
CONTROLS AND FEATURES
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).
Less friction
allows
easier control
lever movement. More friction helps
to hold a steady throttle setting while
cruising.
N (NEUTRAL)
GEARSHIFTRHROTTLE
CONTROL LEVER
17
CONTROLS AND FEATURES
Fast
Idle
Lever
N
(neutral)
MAXIMUM
FAST
IDLE
The fast idle lever is only needed for
starting carbureted outboard models.
The BF200A and BF225A models
use programmed
fuel
injection so,
this lever will not be needed for
starting.
After the engine starts and if the
outside temperature is below
41
OF
(5"C),
the fast idle lever can be used
to accelerate engine warm up.
The fast idle lever will not move
unless the remote control lever is in
the
N
(neutral) position. Conversely,
the remote control lever will not
move unless the fast idle lever is in
the lowest position.
Lower the fast idle lever to the
lowest position to decrease the fast
idle.
Panel-Mount Type
Ignition
Switch
ON
START
OFF
IGNITION
'
SWITCH KEY
\
The ignition switch controls the
ignition system and starter motor.
18
CONTROLS AND FEATURES
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the
ON
position when released
from the START position.
The ignition switch can be used to
operate the starter motor only when
the control lever
(p.
21
)
is
in
the
N
(neutral) position, and the switch clip
is in the emergency stop switch.
Turning the ignition switch to the
OFF
position stops the engine.
Switch Clip and Emergency Stop
Switch
EMERGENCY
STOP SWITCH
SWITCH CLIP
LANYARD
\
SWITCH CLIP
The switch clip must be inserted
in
the emergency stop switch in order
for the engine to start and run. The
lanyard must be attached to the
operator’s PFD (Personal Flotation
Device) or worn around the wrist as
shown.
When used
as
described, the
emergency stop switch and lanyard
system stops the engine if the
operator falls away from the controls.
A spare switch clip
is
stored
in
the
tool bag (optional equipment).
SPARE SWITCH CLIP
19
CONTROLS AND FEATURES
Fast Idle Button
N
(neutral)
FAST
IDLE
BUTTON
By
moving the control lever forward
or reverse when the fast idle button is
pushed in, the throttle opening will
be increased without engaging the
gears.
It is necessary to position the control
lever in
N
(neutral) to push in the fast
idle button.
Gearshift/Throttle Control
Lever
CONTROL LEVER
LEVER
The gearshifdthrottle control lever
controls engine speed and selects
F
(forward),
N
(neutral), or
R
(reverse)
gears.
20
CONTROLS AND FEATURES
Moving the control lever
35"
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 adjusts the operating
resistance
of the control lever.
Less friction allows easier control
lever movement. More friction helps
to hold a steady throttle setting while
cruising.
TH
N (NEUTRAL)
F
(FORWARD) R (REVERSE)
L
35"
MAXIMUM
MAXIMUM
GEARSHIFTRHROTTLE
CONTROL LEVER
21
CONTROLS AND FEATURES
Top-Mount Type
Ignition Switch
ON
START
I
OFF
IGNITION
/\
SWITCH
KEY
The ignition switch controls the
ignition system and starter motor.
Turning the ignition switch key to the
START position operates the starter
motor. The key automatically returns
to the
ON
position when released
from the START position.
The ignition switch can be used to
operate the starter motor only when
the control lever (p.
24
)
is in the
N
(neutral) position, and the switch clip
is in the emergency stop switch.
Turning the ignition switch to the
OFF
position stops the engine.
Switch Clip
and
Emergency Stop
Switch
EMERGENCY
STOP
SWITCH
SWITCH CLIP
\
LANYARD
SWITCH CLIP
22
CONTROLS AND FEATURES
The switch clip must be inserted in
the emergency stop switch in order
for the engine to start and run. The
lanyard must be attached to the
operator’s PFD (Personal Flotation
Device) or worn around the wrist as
shown.
When used as described, the
emergency stop switch and lanyard
system stops the engine
if
the
operator falls away from the controls.
A
spare switch clip is stored in the
tool bag (optional equipment).
SPARE SWITCH CLIP
Fast Idle Button
N (neutral)
F (forward)
.e-,:)
FAST IDLE BUTTON
By
moving the control lever forward
or reverse when the fast idle button is
pushed in, the throttle opening will
be increased without engaging the
gears.
It is necessary to position the control
lever in
N
(neutral)
to
push in the fast
idle button.
Gearshift/Throttle Control
Lever
SINGLE
DUAL TYPE
CONTROL
LEVERS
The gearshifdthrottle control lever
controls engine speed and selects F
(forward),
N
(neutral), or
R
(reverse)
gears.
23
CONTROLS AND FEATURES
Moving the control lever
35"
from
N
(neutral) selects the gear, and further
movement increases engine speed.
A
friction adjuster inside the control
box
adjusts the operating resistance
of the control lever(s).
Less friction allows easier control
lever movement. More friction helps
to hold a steady throttle setting while
cruising.
24
N (NEUTRAL)
F (FORWARD)
R
(REVERSE)
MlNlMUM
\ /
\
\
\
MIPIMUM
E OPENING
\
/
4
MAXIMUM
MAXIMUM
c
0
0
I
I
0
I
REMOAT CONTROL LEVER
CONTROLS AND FEATURES
Common
Controls
Power Trim/Tilt Switch
(side-mount type)
G
R
(top-mount type)
SINGLE TYPE
POWER TRIM/TILT SWITCH
CONTROL
POWER LEVER
TRIM/TILT
SWITCH CONTROL
LEVER
(panel-mount type)
POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH
DUAL TYPE
CONTROL LEVER
The power tridtilt 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 trimhilt
switch anytime the ignition switch is
ON,
whether the boat is underway or
stopped.
Trim the outboard motor to obtain
the best performance and stability (p.
48
).
Tilt the outboard motor
for
shallow
water operation, beaching, launching,
or mooring.
Please tilt up simultaneously, when
you mount the dual type outboard
motor.
25
CONTROLS AND FEATURES
Power Tilt Switch
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.
26
Manual Relief Valve
MANUAL RELIEF VALVE
,NUAL
release)
The outboard motor can be tilted
manually after opening the manual
relief valve. This allows the outboard
motor to be tilted when no battery is
connected.
Tilt Lock Lever
TILT
LOCK
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 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 stem bracket.
CONTROLS AND FEATURES
Engine Cover Latch
ENGINE COVER
LATCH
The engine cover latch fastens the
engine cover to the outboard motor.
Trim Tab
TIGHTENING
YLT
TRIM
*
TAB
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.
57
),
steering effort is
equal in either direction.
INSTRUMENTS
Trim Meter
(optional equipment)
TRIM METER
The trim meter has a range of
0"
to
20"
and indicates the trim angle of
the outboard motor.
Refer to the trim meter when using
the power tridtilt switch to achieve
the best performance from the boat.
27
CONTROLS AND FEATURES
Tachometer
(optional equipment)
t
TACHOMETER
The tachometer shows engine speed
in revolutions per minute.
Refer to the tachometer when using
the throttle and power tridtilt
controls to achieve the best
performance from the boat.
28
INDICATORS
Alternator
(ACG)
Indicator
ACG INDICATOR LIGHT
The
ACG
indicator light turns on and
the buzzer sounds when the charging
system
is
faulty.
Programmed Fuel Injection
(PGM-FI) Indicator
PGM-FI INDICATOR LIGHT
The
PGM-FI
indicator light turns on
and the buzzer sounds when the
engine control system detects a
malfunction, and momentarily
sounds when the ignition key is
turned from
OFF
to
ON.
CONTROLS
AND
FEATURES
Oil
Pressure Indicator
(side-mount type)
(panel-mounVtop-mount types)
When the green light is lit, oil
pressure is
OK.
If
oil pressure becomes low, the
green light will go
off,
and the
engine protection system will limit
engine speed.
Remote controls are also equipped
with a buzzer that sounds when the
green light goes
off.
Low oil pressure indicates that the
engine oil level is low,
or
that there is
a problem with the engine lubrication
system.
Overheating Indicator
(side-mount type)
(panel-mounVtop-mount types)
29
CONTROLS AND FEATURES
If
the engine overheats, the red light
will come on, and the engine will
stop in
20 seconds after the engine
protection system will
limit
engine
speed,
Remote controls are also equipped
with a buzzer that sounds when the
red light comes on.
Engine overheating may be the result
of clogged water intakes.
Cooling System Indicator
COOLING
SYSTEM
INDICATOR
Water should flow
from
the cooling
system indicator while the engine is
running. This shows that water is
circulating through the cooling
system.
If
water stops flowing while the
engine is running, that indicates a
cooling system problem, such as
clogged water intakes, which will
cause engine overheating.
OTHER
FEATURES
Water Contamination
Buzzer
The water contamination buzzer
sounds when water has accumulated
in the water separator.
30
CONTROLS AND FEATURES
Overrev Limiter
The engine is equipped with an
overrev limiter to prevent the
possibility of mechanical damage
from excessive engine speed.
The overrev limiter may be activated
during operation, limiting engine
speed, if the outboard motor is tilted
excessively, or when 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 propeler is
installed.
Anodes
The anodes are made of a sacrificial
material that helps to protect the
outboard motor from corrosion.
There are two anodes on the gear
case, one on the stem bracket, and
two small anodes
in
the water
passages of the engine block.
Fuel Priming Bulb
OUTLET
END
(MOTOR)
PRIMING
BULB
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.
35
).
31
BEFORE
OPERATION
ARE YOU READY TO GET
UNDER WAY
?
Your safety is your responsibility. A
little time spent in preparation will
significantly reduce your risk of
injury.
Knowledge
Read and understand this manual.
Know what the controls do and how
to operate them.
Familiarize yourself with the
outboard motor and its operation
before you get under way. Know
what to
do
in case of emergencies.
Familiarize yourself with all laws
and regulations relating to boating
and the use of outboard motors.
32
Safety
Always wear a PFD (Personal
Flotation Device) while on the boat.
Attach the emergency stop switch
lanyard securely to your PFD or
to
your wrist.
IS
YOUR OUTBOARD
MOTOR READY TO
GO
?
For your safety, and to maximize the
service life of your equipment, it is
very important to take a few
moments before you operate the
outboard motor to check its condition.
Be sure to take care of any problem
you find, or have your authorized
Honda Marine dealer correct it,
before you operate the outboard
motor.
Improperly maintaining
this outboard motor, or
failing to correct
a
problem
before operation, could
cause
a
malfunction in
which you could be
seriously injured.
Always perform
a
preoperation inspection
before each operation, and
correct any problem.
'efore beginning your preoperation
hecks, be sure the ignition switch is
1
the OFF position.
BEFORE OPERATION
Safety Inspection
Look around the outboard motor
for signs of oil or gasoline leaks.
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.
Maintenance Inspection
Check the engine oil level (p. 60
).
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. 74
).
Check that the anodes are securely
attached to the gear case (p. 73
)
and are not excessively worn. The
anodes help to protect the outboard
motor from corrosion.
Make sure the tool kit is onboard
(p.
54
).
Replace any missing items.
Check the fuel level in the fuel
tank (p. 67
).
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. 7
1
).
33
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
on page
7
and the
chapter titled
BEFORE OPERATION.
For your safety, avoid starting or
operating the engine in an enclosed
area. Your engine’s exhaust contains
poisonous carbon monoxide gas
which can collect rapidly
in
an
enclosed area and cause illness or
death.
BREAK-IN PROCEDURE
Break-in period:
10
hours
Proper break-in operation allows the
moving parts to wear in smoothly for
best performance and long service
life.
First
15
minutes:
Run the engine at trolling speed. Use
the minimum throttle opening
necessary to operate the boat at a safe
trolling speed.
Next
45
minutes:
Run the engine up to a maximum of
2,000
to
3,000
rpm, which
is
about
10%
to
30%
of maximum throttle
opening.
Next
64)
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.
34
OPERATION
FUEL
PRIMING
OUTLET END
(MOTOR)
PRIMING BULB
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 squeeze the priming bulb
when the engine is running.
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.
35
OPERATION
STARTING THE ENGINE
Side-Mount
Type
EMERGENCY
STOP ?WITCH
SWITCH CLIP
\
LANYARD
1.
Put the emergency stop switch clip
in
the emergency stop switch, and
attach the lanyard to your PFD
(Personal Flotation Device) or to
your wrist, as shown.
The engine
will
not start
or
run,
unless the clip is in the switch.
The emergency stop switch clip
and lanyard system is a safety
device that will
stop
the engine
if
you fall away from the controls
while operating the boat.
Always attach the lanyard to your
PFD,
or to your wrist, before
starting the engine.
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.
36
OPERATION
FAST IDLE RANGE
3.
Leave the fast idle lever in the
OFF (fully lowered) position.
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.
ON
IGNITION
SWITCH
KEY
4. Turn the ignition switch key to the
START
position and hold it there
until the engine starts.
When the engine starts, release the
key, allowing
it
to return to the
ON
position.
If
the engine fails to start within
5
seconds, release the key and wait
at least
10
seconds before
operating the starter again.
Using the electric starter
f
or more
than
5
seconds at a time will
overheat the starter motor and can
damage it.
Turning the ignition switch key to
the START position while the
engine is running can damage the
starter motor and
f
lywheel.
37
OPERATION
MAXIMUM
FAST
IDLE
--I
@)
5.
Before getting under way, allow
the engine to warm up sufficiently
to ensure good performance.
Above 41°F
(5"C), warm up the
engine for
2
or
3
minutes.
Below 41 OF
(5OC),
warm up the
engine for at least
10
minutes at
2,000
rpm. Raise the fast idle lever
to achieve approximately
2,000
rpm.
During the warm-up period, check
the oil pressure indicator (p. 29
),
overheating indicator (p. 29
),
and
cooling system indicator
(p.
30
).
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.
82
.
6.
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.
38
OPERATION
Panel-Mount
Type
EMERGENCY STOP
SWITCH
SWITCH CLIP
LANYARD
\
1.
Put the emergency stop switch clip
in the emergency stop switch, and
attach the lanyard to your PFD
(Personal Flotation Device)
or
to
your wrist, as shown.
The engine will not start
or run,
unless the clip is in the switch.
The emergency stop switch clip
and lanyard system
is
a safety
device that will stop the engine if
you fall away
from
the controls
while operating the boat.
Always attach the lanyard to your
PFD,
or to your wrist, before
starting the engine.
N
(neutral)
C
L
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.
39
OPERATION
START
SWITCH
KEY
\
3.
Turn the ignition switch key to the
START position and hold it there
until the engine starts.
When the engine starts, release the
key, allowing it to return to the ON
position.
If the engine fails to start within
5
seconds, release the key and wait
at least
10
seconds before
operating the starter again.
Using the electric starter
f
or more
than
5
seconds at
a
time will
overheat the starter motor and can
damage it.
Turning the ignition switch key to
the START position while the
engine
is
running can damage the
starter motor and
f
lywheel.
N
(neutral)
CONTROL
FAST
IDLE
BUTTON
4.
Before getting under way, allow
the engine to warm up sufficiently
to ensure good performance.
Above
41°F
(5"C),
warm up the
engine for
2 or
3
minutes.
Below
41°F
(5"C),
warm up the
engine for at least
10
minutes at
2,000
rpm. Push the fast idle
button then move the control lever
forward or reverse to open the
throttle and achieve approximately
2,000
rpm.
OPERATION
~~
During the warm-up period, check
the oil pressure indicator (p.
29
),
overheating indicator (p.
29
),
and
cooling system indicator (p.
30
).
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.
82.
5.
If the fast idle control 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
SWITCH CLIP LANYARD
1.
Put the switch clip in the
emergency stop switch, and attach
the lanyard to your PFD (Personal
Flotation Device) or to your wrist,
as shown.
The engine will not start or run,
unless the clip is in the switch.
The emergency stop switch clip
and lanyard system is a safety
device that will stop the engine if
you fall away from the controls
while operating the boat.
Always attach the lanyard to your
PFD, or to your wrist, before
starting the engine.
41
OPERATION
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.
START
IGNITION
.
SWITCH
\
KEY
3.
Turn the ignition switch key to the
START position and hold it there
until the engine starts.
When the engine starts, release the
key, allowing
it
to return to the
ON
position.
If the engine fails to start within
5
seconds, release the key and wait
at least
10
seconds before
operating the starter again.
I
NOTICE
I
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.
42
OPERATION
N
(neutral)
FAST IDLE BUTTON
4.
Before getting under way, allow
the engine to warm up sufficiently
to ensure good performance.
Above
41
"F
(5"C),
warm up the
engine for 2
or
3
minutes.
Below
41
"F
(5"C),
warm up the
engine for at least
10
minutes at
2,000
rpm. Push the fast idle
button then move the control lever
forward or reverse to open the
throttle and achieve approximately
2,000 rpm.
During the warm-up period, check
the oil pressure indicator (p. 29
),
overheating indicator (p. 29
),
and
cooling system indicator (p.
30).
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.
82.
5.
If the fast idle control was used to
warm up the engine, gradually
return the control lever to the
N
(neutral) position
as
the engine
warms up.
STOPPING THE ENGINE
Emergency Engine Stopping
Side-Mount Type
EMERGENCY
STOP SWITCH
Panel-MountITop-Mount Types
\
//
LANYARD
SWITCH CLIP
43
OPERATION
To
stop
the
engine in an emergency,
pull the clip out
of
the emergency
stop switch by pulling the lanyard.
We suggest that
you
stop the engine
this way occasionally
to
verify that
the engine and emergency stop
switch
is
operating properly.
44
Normal
Engine Stopping
Side-Mount Type
I
N
(neutral)
Panel-Mount Type
N
(neutral)
W
Top-Mount Type
N
(neutral)
LEVER
1.
Move the control lever(s) to the
N
(neutral) position.
OPERATION
Side-Mount Type
Panel-Mount/Top-Mount Types
OFF
IGNITION KEY
\
2.
Turn the ignition switch key to the
OFF
position.
3.
When the boat is not in use,
remove and store the ignition key
and the emergency stop switch clip
and lanyard.
GEARSHIFTING AND
THROTTLE
OPERATION
Side-Mount Type
CONTROL LEVER
GUL
RELEASE LEVER
N (neutral)
n
F
(forward)
45
OPERATION
Panel-Mount Type
N (neutral)
To
shift gears, move the control lever
to select
F
(forward),
N
(neutral) and
R
(reverse) gears.
The control lever cannot be moved
from the
N
(neutral) position unless
the neutral release lever
is squeezed
t$$&
\,
,/'.
I
(side-mountlpanel-mount types).
LEVER
Top-Mount Type
N (neutral)
F(forWqh R (reverse)
CONTR
LEVER
Moving the control lever beyond the
gear selection range increases engine
speed.
Side-Mount Type
TO INCREASE
TO DECREASE
FRICTION
ADJUSTER FRICTION
.
Panel-Mount Type
CONTROL LEVER
FRICTION ADJUSTER
\
TO INC
FRICTJ
TO DECREASE
FRICTION
46
OPERATION
Top-Mount Type
0
FRICTION
I
CONTROL LEVER
FRICTION ADJUSTER
Adjust the throttle friction adjuster
so
the control lever will hold a constant
throttle setting while cruising.
STEERING
Steer the boat in the same manner
as
an automobile.
47
OPERATION
CRUISING
Engine Speed
For best fuel economy, limit the
throttle opening to
80%.
Use the
throttle friction control (p.
46
)
to
help you hold a steady speed.
For rough water conditions or large
waves, slow down to prevent the
propeller from rising out
of
the water.
The engine is equipped with an
overrev limiter to prevent the
possibility of mechanical damage
from excessive engine speed.
If, for example, the outboard motor
is tilted excessively, or 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
48
motor.
Trim
Use the power trimhilt switch to trim
the outboard motor for the best
performance and stability.
You
can use the power tridtilt
switch at any time, whether the boat
is
under way 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.
27) for an
indication of whether the boat 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.
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 tridtilt angle during
operation can cause propeller
ventilation, overheating, and water
pump damage.
OPERATION
Side-Mount Type
Panel-Mount Type
POWER TRIM/TILT SWITCH
Top-Mount Type
(single
type)
POWER TRIM/TILT SWITCH
(dual
type)
POWER TRIM/TILT SWITCH
(RIGHT)
MOTOR MOTOR
TRIMMED TOO
TRIMMED TOO
LOW
HIGH
MOTOR TRIMMED
CORRECTLY
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
49
OPERATION
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.
TIGHTENING BOLT
TRIM
TAB
Adjust the trim tab with the engine
stopped. Loosen the bolt above the
trim tab, turn the trim tab, then
tighten the bolt securely.
When the trim tab is correctly
adjusted, steering effort will be equal
in both directions.
SHALLOW
WATER
OPERATION
When operating in shallow water, use
the power trimhilt switch (p.
49
)
to
tilt
the outboard motor,
so
the
propeller and gear case won’t hit the
bottom.
Proceed at low speed, and monitor
water flow from the cooling system
indicator (p.
30)
to be sure the
outboard motor
is
not tilted
so
high
that the water intakes are out of the
water.
piKq
An excessive tridtilt angle during
operation can cause propeller
ventilation, overheating, and water
pump damage. This type
of
damage
is not covered
by
the Distributor’s
Limited Warranty.
MOORING, BEACHING,
LAUNCHING
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 as far as it will
go,
move the tilt lock lever to the LOCK
position, then gently lower the
outboard motor until the lever
contacts the stern bracket.
If
more clearance
is
needed to swing
the tilt lock lever into the LOCK
position, rock the outboard motor
back slightly by pulling on the engine
cover grip.
To
lower the outboard motor, tilt up,
move the tilt lock lever to the
FREE
position, then lower the outboard
motor to the desired position.
OPERATION
POWER
TILT
SWITCH
\
TILT
LOCK
LEVER
(Lock
position)
I
pimi-
Do not attempt to use the power tilt
switch to tilt the outboard motor
down while the tilt lock lever is in the
lock position. Damage to the power
tilt system may occur.
MANUAL RELIEF VALVE
\
(To
fix)
The outboard motor can also be tilted
manually after opening the manual
relief valve. This feature enables the
outboard motor to
be
tilted or
lowered 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
motor will tilt up when operated in
reverse.
51
SERVICING YOUR OUTBOARD MOTOR
THE IMPORTANCE
OF
MAINTENANCE
Good maintenance is essential for
safe, economical, and trouble-free
operation.
It
will also help reduce air
pollution.
Improperly maintaining
this outboard motor, or
failure to correct
a
problem
before operation, can cause
a
malfunction in which you
could be seriously hurt or
killed.
Always follow the
inspection and
maintenance
recommendations and
schedules in this owner‘s
manual.
To
help you properly care for your
outboard motor, the following pages
include a maintenance schedule,
routine inspection procedures, and
simple maintenance procedures using
basic hand tools. Other service tasks
that are more difficult,
or
require
special tools, are best handled by
professionals and are normally
performed by a Honda technician or
other qualified mechanic.
The maintenance schedule applies to
normal operating conditions. If you
operate your outboard motor under
unusual conditions, consult an
authorized Honda marine dealer for
recommendations applicable to your
individual needs and use.
Remember that your authorized
Honda marine dealer knows your
outboard motor best and is fully
equipped to maintain and repair it.
To ensure the best quality and
reliability, use only new, genuine
Honda parts or their equivalents for
repair and replacement.
Maintenance, replacement, or
repair of the emission control
devices and systems may be
performed by any marine engine
repair establishment or individual,
using parts that are “certified” to
EPA standards.
52
SERVICING YOUR OUTBOARD MOTOR
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.
53
SERVICING YOUR
OUTBOARD
MOTOR
TOOL
KIT
(optional equipment)
The following tools are supplied by
your dealer for simple maintenance
procedures
and
emergency repairs.
Keep these items on the boat,
so
they
will always be available if you need
them.
r
-l
\
\.
-
OIL
CHECK
OWNER'S MANUAL FUSE PULLER
16
X
17 mm
BOX WRENCH
L
J
SCREWDRIVER
-
-
s==s
-
l4
x
l7
WRENCH
SPARK PLUG WRENCH
lo
x
l2
mm
WRENCH
19
mm
EYE WRENCH
-
8
mm WRENCH
FLAT SCREWDRIVER
*
-
SCREWDRIVER HANDLE
-
SPARE SWITCH CLIP PHILLIPS
TOOL BAG
e
PLIERS
r
6
mm
HEX. WRENCH
54
SERVICING
YOUR OUTBOARD
MOTOR
MAINTENANCE SCHEDULE
r\
REGULAR SERVICE PERIOD
(3)
I\
Perform at every indicated month
or
operating
hour interval. whichever comes first.
First month
I
Each use
I
After
use
I
or
\
20
hrs.
ITEM
0
1
Engine oil Check level
0
\
I I I
...
.
*
0
1
Engine oil Check level
0
Every
6
months
400
hrs.
200
hrs.
100
hrs.
or
or
or
Every
2
years Every year
0
0
(2)
Emission related items.
(I)
Lubricate more frequently when used
in
salt water.
(2)
These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.
(3)
For
professional commercial use, log hours of operation to determine proper maintenance intervals.
(4)
When operating in salt water, turbid
or
muddy water, the engine should be flushed with clean water after each use.
Refer to the Honda shop manual for service procedures.
SERVICING YOUR OUTBOARD MOTOR
REGULAR SERVICE PERIOD
(3)
Perform at every indicated month
or
operating
hour interval,
whichever
comes
first.
Each
use
\
ITEM
@
I
Fuel filter Check
Replace
Fuel
filter Replace
(High
pressure
type)
Thermostat Check
0
Fuel line Check
I
After
usc
First month
or
20
hrs.
L
Every
6
months Every year Every
2
years
100
hrs.
I
20006rs.
1
40rhrs.
or
I
I
0
n
I
I
0
(2)
U
I I
I I
0
(2)
I
I I
Replace
Every
2
years
(If
necessary)
(2)
Battery
and cable Check level-tightness
connection
0
0
(2)
0
(2)
Bolts and Nuts Check-tightness
Cooling water passages Clean
0
(4)
0
0
(2)
Crankcase breather tube Check
Emission related items.
(1)
Lubricate more frequently when used in salt water.
(2)
These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and
are
mechanically proficient.
(3)
For
professional commercial
use,
log hours
of
operation
to
determine proper maintenance intervals.
(4)
When operating in salt water, turbid
or
muddy water, the engine should be flushed with clean water after each use.
Refer
to
the Honda shop manual for service procedures.
SERVICING YOUR OUTBOARD MOTOR
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, loosen
the trim tab bolt and adjust the angle
of the trim tab. Retighten the trim tab
bolt securely.
TIGHTENING BOLT
I
LEFT
I
If less effort is required to make left
turns, move the back of the trim tab
left.
TIGHTENING BOLT
I
RIGHT
I
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.
57
SERVICING YOUR OUTBOARD MOTOR
MANUAL RELIEF VALVE
MANUAL RELIEF VALVE
NUAL
release)
The outboard motor can be tilted
manually after opening the manual
relief valve. This feature enables the
outboard motor to be tilted or
lowered 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.
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.
58
ENGINE COVER REMOVAL
AND INSTALLATION
k
ENGINE
COVER
The engine cover latch fastens the
engine cover to the outboard motor.
To remove the engine cover, pull the
engine cover latch to the unlocked
position, then lift the engine cover
straight up from the outboard motor.
To
install the engine cover, place the
cover on the outboard motor, and
push down evenly.
SERVICING YOUR OUTBOARD MOTOR
Latch Adjustment
A loose engine cover may rattle or
allow water to enter. Check whether
the engine cover fits properly and
adjust if necessary.
Engine Cover Clearance
Inspection
FRONT
INSPEC~ION
POINT
REAR
I
Q
i
(4.8
-
5.8'mm)
in
P
INSPECTION POINT
With the engine cover in place,
measure the clearance between the
engine cover and the engine
undercase at the latch.
Specified engine cover clearance:
0.19
-
0.23
in
(4.8
-
5.8
mm)
If the clearance
is
outside the
specified range, adjust the cover lock
bolt.
Cover Lock Bolt Adjustment
1.
Remove the engine cover.
I
I
NUT
COVER
LOCK
BOLT
2. Loosen or tighten the nuts on the
front and/or side cover lock bolts,
and move the bolt
(s)
as necessary
to obtain the specified engine
cover clearance.
3.
After adjustment, install the engine
cover securely.
4. Recheck the engine cover
clearance, and readjust if necessary.
59
SERVICING YOUR OUTBOARD MOTOR
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.
58
).
2. Remove the dipstick and wipe it
clean.
OIL
LEVEL
DIPSTICK
3.
Insert the dipstick all the way in,
then remove it and check the oil
level
shown on the dipstick.
OIL FILLER CAP
4.
If the oil level is low, remove the
oil filler cap, and add oil to reach
the upper limit mark shown on the
dipstick. Use the oil recommended
on p. 62.
(NOTlCEI
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.
Engine Oil Change
An engine oil evacuation/filling
device may be used to remove/add
the engine oil.
Drain the used oil while the engine is
warm. Warm oil drains quickly and
completely.
1.
Unlock and remove the engine
cover
(p.
58
).
DRAIN PLUG SCREW
DRAIN
PLUG
COVER
2. Remove the screw from the oil
drain plug cover, and remove the
cover.
SERVICING YOUR OUTBOARD MOTOR
DRAIN
PLUG
3.
Place a suitable container below
the oil drain guide to catch the
used oil, then remove the oil filler
cap and the drain plug.
4.
Allow the used oil to drain
completely, then reinstall the
engine oil drain plug, and tighten it
securely.
Improper disposal
of
engine oil
can be harmful to the environment.
If
you change your
own
oil,
please
dispose
of
the used oil properly.
Put it in a sealed container, and
take it to a recycling center.
Do
not discard it in a trash bin or
dump it on the ground.
5.
Install the oil drain plug cover and
secure
it
with the screw.
6. With the outboard motor in a
vertical position, fill to the upper
limit mark
on
the dipstick
(p.
60
)
with the recommended oil.
Engine oil refill capacity:
Without oil filter change:
8.0
US
qt
(7.6
Q,
6.7
Imp
qt)
7.
Install the oil filler cap and tighten
it
securely.
8.
Install and lock the engine cover.
SERVICING
YOUR
OUTBOARD MOTOR
Engine Oil Recommendations
Oil is a major factor affecting
performance and service life. Use
4-stroke automotive detergent oil.
l-FR++l
SAE
Viscosity
Grades
-30
-20
-10
0
10
20
30
40°C
AMBIENT TEMPERATURE
SAE
1
OW-30
is recommended for
general use.
The
SAE
oil viscosity and service
classification are in the
API
label on
the oil container. Honda recommends
that you use
API
SERVICE
category
SG,
SH or
SJ
oil with the “starburst”
certification mark displayed on the
container.
62
SERVICING
YOUR
OUTBOARD
MOTOR
Lubrication Points
Wipe the outside of the engine with a cloth dipped in oil.
6
ENGINE
COVER
ARM
SHAFT
Apply marine anticorrosion grease to the following parts:
Lubrication interval:
After the first
20
hours or
1
month, then every
100
hours
or
6
months. (Refer
to
the maintenance schedule page
THROTTLE AMSHIFT
55
).
Apply anticorrosion oil to pivot surf aces where greas
cannot penetrate.
SWIVEL
TILT
LOCK LEVEWSHAFT CAM
Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover except the belts.
63
SERVICING YOUR OUTBOARD MOTOR
Spark
Plug
Service
RECOMMENDED
SPARK
PLUGS:
IZFRGFll
(NGK)
VKJ20RZ-M11
(DENSO)
pEl
Incorrect spark plugs can cause
engine damage.
1.
Disconnect the battery negative
(-)
terminal.
2.
Unlock and remove the engine
cover (p.
58
).
SPECIAL
SCREWS
L.ENGINE UNDER
COVER
3.
Remove the twenty special bolts,
and remove the R. and
L.
engine
under covers.
WIRE
IGNITION COIL
CONNECTOR
\
4.
Disconnect the wire connector
from the ignition coil by pushing
on the lock tab and pulling on the
connector. Pull on the plastic
connector, not the wires.
5.
Use a hex. wrench to remove the
bolt holding the ignition coil.
Remove the ignition coil by
pulling it up slightly.
64
SERVICING
YOUR OUTBOARD MOTOR
SPARK
PLUG
WRENCH
6.
Remove the spark plugs with
a
spark plug wrench and 17 mm
wrench.
7.
Inspect the spark plugs. Replace
them if the electrodes are worn, or
if the insulators are cracked or
chipped.
8.
Measure the spark plug electrode
gap with a suitable gauge. The gap
should be
0.039
-
0.051
inches
(1.00
-
1.30
mm). If the gap
is
out of the speciticution, replace the
plug with
a
new
one.
Never
try
to
readjust the gap.
9. Install the spark plugs carefully,
by
hand, to avoid cross-threading.
10.
After each spark plug seats, tighten
with a spark plug wrench supplied
in
the tool kit to compress the
sealing washer.
If reinstalling the used spark plugs,
tighten
1/8
-
1/4
turn
after the
spark plugs seat.
If reinstalling new spark plugs,
tighten
1/2
turn after the spark
plugs seat.
I
NOTICE
I
Loose spark plugs can overheat
and damage the engine.
Overtightening the spark plugs
can damage the threads in the
cylinder head.
65
SERVICING YOUR OUTBOARD MOTOR
11.
Install the ignition coil. Reinstall
the bolt.
12. Push the wire connector onto the
ignition coil. Make sure it locks in
place.
13.
Repeat this procedure for the other
five spark plugs.
14.
Reinstall the covers. When
reinstalling the covers, make sure
not
to
jam the wire harnesses in
between the covers and engine
case.
66
SERVICING
YOUR
OUTBOARD MOTOR
REFUELING
Check the fuel level and refill if
neccessary.
Do
not fill the fuel tank
above the
UPPER
LIMIT.
Refer to
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.
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.
Wipe up spills immediately.
67
SERVICING YOUR OUTBOARD MOTOR
FUEL
RECOMMENDATIONS
Use unleaded gasoline with a
pump
octane rating
of
86
or
higher.
These outboard motors are certified
to operate on unleaded gasoline.
Unleaded gasoline produces fewer
engine and spark plug deposits and
extends exhaust system life.
Never use stale or contaminated
gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel
tank.
Occasionally you may hear a light
“spark knock” or “pinging”
(metallic rapping noise) while
operating under heavy loads. This is
no cause for concern.
If spark knock or pinging occurs at a
steady engine speed, under normal
load, change brands of gasoline. If
spark knock
or
pinging persists, see
an authorized Honda marine dealer.
68
-1
Running the engine with persistent
spark knock
or
pinging can cause
engine damage.
Running the engine with persistent
spark knock or pinging is misuse,
and the
Distributor’s Limited
Warranty
does not cover parts
damaged by misuse.
Fuel Pump Filter Inspection
and Replacement
The fuel pump filter (inside the
strainer cup) is located below the
engine oil filter.
Water or sediment accumulated in
the filter can cause loss
of power or
hard starting.
To
prevent engine
malfunction, inspect the filter and
replace when necessary.
SERVICING YOUR 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.
ENGINE COVER LATCH
1.
Remove the engine cover.
69
SERVICING
YOUR
OUTBOARD
MOTOR
Id
FUEL FILTER (inside strainer
cup)
2. Looking through the translucent
strainer cup, check the fuel filter
for water accumulation or
sediment.
SCREW
(3)
FUEL HOSES
\
SUSPENSION STRAP
3.
Remove the suspension strap from
the strainer bracket, then remove
the strainer assembly from the
strap.
Before removing the
fuel
filter, to
prevent fuel leakage, place fuel
hose clamps on the fuel hoses at
the each side of the fuel filter.
4.
Remove the three screws and
separate the fuel strainer cup from
the strainer body.
5.
Thoroughly clean the strainer cup,
and replace with
a new
fuel filter.
6.
Reassemble the strainer body and
the cup.
STRAINER
TIGHTENING
TORQUE:
3.4
N.m
(0.35
kgf-m
,
2.5
Ibf-ft)
7.
Reinstall the strainer in
the
original
position.
70
SERVICING YOUR OUTBOARD
MOTOR
8.
Prime the engine using the priming
bulb (refer to page
35).
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.
Water Separator Inspection and
Service
WATER
SEPARATOR
Water separator is located beside the
oil level dipstick. Water
accumulation in the water separator
can cause loss of power or hard
starting. Check the water separator
periodically. Clean it or consult with
an authorized Honda outboard motor
dealer for clean.
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.
71
SERVICING YOUR OUTBOARD MOTOR
SUSPENSION
STRAP
I
FUELTUBES
SCREW
(3)
1.
Remove the engine cover (see
page
58).
2. Disconnect the water level sensor
connector.
3.
Remove the suspension strap from
the water separator bracket, then
remove the separator assembly
from the strap.
4.
Pinch the fuel tubes with tube clips
to
prevent fuel leakage.
5.
Remove the three screws and
separate the water separator cup
from the body.
6.
Thoroughly clean the water
separator cup.
7.
Reassemble the water separator
body and the cup.
TIGHTENING TORQUE:
3.4
N-m
(0.35
kgfmm
,2.5
Ibf-ft)
8.
Reinstall the strainer in the reverse
order of removal.
9.
Squeeze and release the priming
bulb to fill the vapor separator, and
check for leaks.
If the buzzer sounds
or
water or
sediment accumulation
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.
72
SERVICING YOUR OUTBOARD MOTOR
Anode Replacement
ANODE
(stern bracket)
ANODE
(each
side)
The anodes are located on each side
of the gearcase. They
are
made
of
a
sacrificial material that helps to
protect the outboard motor from
corrosion.
Replace the anodes when they have
been reduced to about half their
original size, or
if
they are crumbling.
piq
Painting
or
coating the anodes will
defeat 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.
73
SERVICING YOUR OUTBOARD MOTOR
Propeller Replacement
Before replacing the propeller,
remove the clip from the engine stop
switch to prevent any possibility of
the engine being started while you
are working with the propeller.
The propeller blades may have sharp
edges,
so wear heavy gloves to
protect your hands.
Removal
1.
Remove the cotter pin, unscrew
the castle nut, remove the washer,
then remove the propeller and
thrust washer.
2. Inspect the propeller shaft for any
fishing line or debris.
74
Installation
1.
Apply marine-grade grease to the
propeller shaft and beveled surface
of the thrust washer.
2.
Install the propeller in the reverse
order of removal.
-1
Install the thrust washer with the
grooved side toward the gear case.
Use a genuine Honda cotter
pin
and bend the
pin
ends as shown.
-
PROPELLER
CASTLE
NUT
STORAGE
STORAGE PREPARATION
Proper storage preparation is
essential for keeping your outboard
motor troublefree and looking good.
The following steps will help to keep
rust and corrosion from impairing
your outboard motor’s function and
appearance, and will make the engine
easier to start when you use the
outboard motor again.
Cleaning and Flushing
Thoroughly clean and flush the
outboard motor with fresh water after
operation in dirty water or salt water.
Touch up any damaged paint, and
coat areas that may rust with a light
film of oil. 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 described
on p.
30.
Flushing With the Honda
Garden Hose Adapter
(commercially available)
When using the Honda garden hose
adapter (commercially available), do
not to run the engine during the
flushing procedure.
For safety, remove the emergency
stop switch clip
so
the engine cannot
be started while you are standing near
the propeller.
FLUSH
PULG
CONNECTOR
1.
Remove the flush plug connector.
75
STORAGE
FLUSH PLUG
CONNECTOR
WATER
HOSE
(Commercially available)
2. Screw the water hose into the flush
plug connector.
3.
Turn
on the fresh water
supply
and
flush the outboard motor for at
least
10
minutes.
4.
After flushing, remove the garden
hose adapter, and install the flush
plug cap.
76
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 separetor deteriorates during
storage, you may need to have the
vapor separetor and other fuel system
components serviced or replaced.
The length of time that gasoline can
be left in your
fuel
tank and vapor
separetor without causing functional
problems will
vary
with such factors
as gasoline blend, your storage
temperatures, and whether the fuel
tank is partially or completely filled.
The air in a partially filled
fuel
tank
promotes fuel deterioration. Very
warm storage temperatures accelerate
fuel deterioration. Fuel deterioration
problems may occur within a few
months, or even less if the gasoline
was not fresh when you filled the
fuel tank.
The
Distributor’s Limited Warranty
does not cover fuel system damage
or engine performance problems
resulting from neglected storage
preparation.
You can avoid fuel deterioration
problems by draining the fuel tank
and vapor separetor.
VAPOR SEPARATOR
I
I
1. Unhook the drain hose from the
lower left of the head cover.
2.
Set the end of the hose toward the
outside of the engine undercase.
3.
Loosen the vapor separator drain
bolt.
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.
77
STORAGE
4. Tilt
up
the outboard motor.
5.
Tilt down the outboard motor, and
drain the vapor separator.
6. After draining thoroughly, tighten
the drain bolt securely.
7.
Clip the drain hose on the head
cover.
8.
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.
Engine
Oil
1.
Change the engine oil (p.60
-
61
).
2.
Remove the spark plugs (p.
64
),
and remove
the
clip from the
emergency stop switch.
3.
Pour a tablespoon
(5
-
10
cm3)
of
clean engine oil into each cylinder.
4.
Rotate the engine a few
revolutions to distribute the oil in
the cylinders.
5.
Reinstall the spark plugs (p.
65
).
HOISTING THE
OUTBOARD
MOTOR
/a/
ENGINE
COVER
/LATCH
I.
Unlock and remove the engine
cover.
78
STORAGE
S
2. Attach the hoist hooks to the
lifting eyes.
3.
Disconnect the outboard motor
from the boat, hoist the outboard
motor, and move
it
to the storage
area.
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
sparkproducing electric motor, or
where power tools are operated.
If the outboard motor will be
removed from the boat for storage,
we recommend storing
it
vertically
by mounting it on a stand.
79
STORAGE
PROTECTOR
If it is necessary to store the outboard
motor horizontally, drain the vapor
separator
(p.
77
),
and drain the
engine oil (p.
60
),
before removing
the outboard motor from the boat.
Rest the motor on and cushion
of
protective packing material.
Cover the outboard motor to keep out
dust.
Do not use sheet plastic as a
dust cover.
A
nonporous cover will
trap moisture, promoting rust and
corrosion.
REMOVAL FROM STORAGE
Check your outboard motor as
described in the
BEFORE
OPERATION
chapter
of
this manual.
If the cylinders were coated with oil
during storage preparation, the
engine may smoke briefly at startup.
This is normal.
80
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.
MOTOR SUPPORT
BAR
(commercially available)
TRANSPORTING
WITH OUTBOARD MOTOR
REMOVED FROM BOAT
Secure the outboard motor in either
the vertical or horizontal position
shown on p.
79
-
80.
81
TAKING CARE
OF
UNEXPECTED PROBLEMS
ENGINE
WILL
NOT
START
1.
Check emergency stop switch
clip.
2. Check control positions.
Possible Cause Correction
Clip not inserted in stop switch. Insert clip in stop switch.
Control lever not
in
neutral
position.
Shift to neutral.
Fast idle lever raised (side-mount Leave fast idle lever
OFF
(p.
18
).
type).
82
TAKING CARE
OF
UNEXPECTED PROBLEMS
ENGINE WILL NOT START
(continued)
3.
Check fuel.
Possible Cause
Out of fuel.
Fuel hose not primed.
Fuel pump filter or fuel tank filter
clogged.
Bad fuel; boat stored without
treating or draining gasoline, or
refueled with bad gasoline.
Correction
Refuel (p. 67
),
Squeeze priming bulb (p.
31
).
Replace fuel filters (p. 69
).
Drain fuel tank and vapor
separator (p. 77
).
Refill with fresh
gasoline (p. 67
).
83
TAKING CARE
OF
UNEXPECTED PROBLEMS
ENGINE WILL NOT START
(continued)
4. Check battery.
Possible Cause Correction
Battery connections loose or
connections.
corroded.
Clean and tighten battery
Recharge battery.
Battery discharged.
~~~ ~ ~ ~~~~~~~
5.
Check fuses.
1
Fuse(s) burnt out.
I
Replace fuse(s) (p.
87
).
6.
Remove and inspect spark plugs. Spark plugs faulty, fouled or
improperly gapped.
Clean, gap or replace spark plugs
1
(P.64
1.
Spark plugs wet with fuel (flooded
engine with the throttle open.
engine).
Dry and reinstall spark plugs. Start
7.
Use starting procedure (p. 36
),
Replace or repair faulty Fuel system malfunction, fuel
then take outboard motor to an
switch malfunction, or electrical or refer to the shop manual.
stuck valves, starter malfunction,
authorized Honda Marine dealer,
components as necessary.
pump failure, ignition malfunction,
problem in the starting circuit, etc.
84
TAKING CARE
OF
UNEXPECTED PROBLEMS
HARD
STARTING OR STALLS
Correction
Possible Cause
AFTER STARTING
1.
Check control positions.
2.
Check fuel.
Fast idle lever raised (side-mount
type).
Fuel hose not primed.
Fuel pump filter
or
fuel tank
clogged.
Leave fast idle lever
OFF
(p.
18
).
Squeeze priming bulb (p.
31
).
Replace fuel filters (p. 69
).
Bad fuel; boat stored without
treating or draining gasoline, or
refueled with bad fuel.
Drain fuel tank and vapor
separator (p. 77). Refill with fresh
gasoline (p. 67).
85
TAKING CARE
OF
UNEXPECTED PROBLEMS
HARD STARTING OR STALLS
(continued)
AFTER STARTING
Possible Cause
3.
Remove and inspect spark plugs.
Spark plugs faulty, fouled or
improperly gapped.
4.
Take outboard motor to an
Fuel system malfunction, fuel
authorized Honda Marine dealer,
etc.
or refer to the shop manual.
pump failure, ignition malfunction,
Correction
Clean, gap or replace spark plugs
(P. 64
>.
~
Replace or repair faulty
components as necessary.
.
ENGINE OVERHEATS
I
Possible Cause
I
Correction
I
1.
Check water intake screens.
1
Water intake screens clogged.
1
Clean water intake screens.
I
2.
Take outboard motor to an
Replace or repair faulty Faulty thermostat or water pump.
authorized Honda Marine dealer,
or refer to the shop manual.
components as necessary.
86
TAKING
CARE
OF
UNEXPECTED PROBLEMS
BATTERY
WILL
NOT
CHARGE AND ELECTRIC
STARTER
WILL
NOT
OPERATE
The battery-charging (ACG) circuit
and the electric starter relay circuit
are protected by the
10,
15 and
30-
ampere main fuses and 150-ampere
ACG fuse. If the fuse burns out, the
engine will not charge the battery,
and the electric starter will not
operate.
The ignition switch is protected by
the 10-ampere main fuse. If the fuse
bums out, the engine will not start
or
run, and the power tridtilt switch
will not oprate.
Fuse Replacement
Main
Fuse
1.
With the engine stopped, remove
the engine cover.
2.
Remove the fuse covers.
3.
Remove and inspect the fuses.
If
a
fuse is burnt out, install a
replacement fuse of the specified
rating. The outboard motor is
supplied with spare fuses in the
fuse holders.
MAIN
FUSES:
10
A,
15
A,
30
A
WI
Never use a fuse with a rating
greater than specified. Serious
damage to the electrical system
could result.
FUSES (10A. 15A. 30A)
I
SPARE
FUSES
FUSE
CASE
(lOA,
15A,
30A)
4.
Reinstall the fuse covers and the
engine cover.
Before further operation, try to
determine and correct the electrical
problem that caused the fuse to
burn
out.
An uncorrected electrical
problem may cause the fuse to
bum out again.
87
TAKING CARE
OF
UNEXPECTED PROBLEMS
Fuse
FUSE (150A)
FUSE CASE
LID
/
SPARE
FUSE
Disconnect the battery cable at
the battery negative
(-)
terminal
before replacing the
f
use.
Failure
to
do
so
may cause
A
short circuit.
Replacement
1.
Stop the engine.
2. Remove the engine cover.
3.
Remove the fuse case lid.
4.
Remove the old fuse by removing
two
5
mm
screws.
5.
Install a new fuse with the
“150
A” mark downward.
ACG
FUSE:
150
A
6.
After finishing replacement, install
the fuse case lid with its hook
toward the engine side.
7.
Be sure to check the fuse case lid
is securely locked.
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
“150
A” mark on it.
88
TAKING CARE
OF
UNEXPECTED PROBLEMS
OIL PRESSURE INDICATOR
LIGHT GOES
OFF
AND
ENGINE SPEED IS LIMITED
Side-Mount Type
Panel-Mount/Top-Mount Types
If oil pressure becomes low, the
green indicator light will go off, and
the engine protection system will
limit engine speed. If you are at
cruising speed, engine speed will
decrease gradually.
Oil pressure indicator is also
equipped with a buzzer that sounds
when the green indicator light goes
off.
Low oil pressure may be the result
of
a low engine oil level, or there may
be a problem with the engine
lubrication system.
If the throttle is closed suddenly after
full throttle operation, engine speed
may drop below the specified idle
rpm, and that could activate the
engine protection system
momentarily.
If low oil pressure activates the
engine protection system, stop the
engine, check the engine oil level (p.
60
),
and add oil
if
needed.
With the engine oil at the
recommended level, restart the
engine. If the lubrication system is
OK,
the green indicator light should
come
on
within 30 seconds, and the
engine will respond normally to
throttle 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.
89
TAKING CARE
OF
UNEXPECTED PROBLEMS
OVERHEATING INDICATOR
LIGHT COMES ON AND
ENGINE SPEED IS LIMITED
Side-Mount Type
Panel-Mount/Top-Mount Types
90
If the engine overheats, the red
indicator light will come on, and the
engine will stop in
20
seconds after
the engine protection system will
limit engine speed.
If
you are at
cruising speed, engine speed will
decrease gradually.
Remote-control types are equippe
d
with a buzzer that sounds whenthe
red indicator light comes on.
Engine overheating may be the result
of
clogged water intake screens, or
there may be a problem with the
cooling system thermostat or water
pump.
If the engine
is
stopped after running
at
full
throttle, and then restarted
soon afterward, that could activate
the engine protection system
momentarily.
COOLING SYSTEM INDICATOR
/
If overheating activates the engine
protection system, idle the engine in
neutral, and check the cooling system
indicator.
If water
is
flowing from the cooling
system indicator, continue idling for
30
seconds. If the cooling system
is
OK,
the red indicator light should go
off within
30
seconds, and the engine
will respond normally to throttle
control lever operation.
TAKING CARE OF UNEXPECTED PROBLEMS
If there is no water flowing from the
cooling system indicator, stop the
engine, and tilt the outboard motor to
inspect the water intake screens. If
clogged, clean the water intake
screens, return the outboard motor to
the running position, restart the
engine, and check the cooling system
indicator again.
If there is still no water flowing from
the cooling system indicator, or if the
engine protection system remains
activated after
30
seconds, return to
the nearest boat landing, and have the
outboard motor inspected by an
authorized Honda marine dealer.
WATER CONTAMINATION
BUZZER SOUNDS
WATER
SEPARATOR
When the water contamination
buzzer sounds:
1.
Check the water separator for
water contamination.
If
water is
accumulated, stop the engine, and
clean the water separator following
the instructions on page
72
,
or
consult with an authorized Honda
outboard motor dealer.
SUBMERGED MOTOR
A
submerged outboard motor must
be serviced immediately after it is
recovered from the water in order to
minimize corrosion.
If there is a Honda marine dearship
nearby, take the motor to the dealer
immediately. If you are far from a
dealership, proceed as follows:
1.
Remove the engine cover, and
rinse the outboard motor with
fresh water to remove salt water,
sand, mud, etc.
2.
Drain the vapor separator as
described on p.
77.
91
TAKING CARE
OF
UNEXPECTED PROBLEMS
3.
Change the engine oil as described
on p. 60
-
61
.
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. 64).
Operate the starter to expel1 water
from the engine’s cylinder.
5.
Put a teaspoon 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).
pEE1
Running the outboard motor without
sufficient cooling water will damage
the water pump and overheat the
engine.
If the engine fails
to
start,
remove
the spark plugs, clean and dry
them, then reinstall the spark plugs
and attempt to start the engine
again.
If
the engine
starts,
and no
mechanical damage is evident,
continue to run the engine for a
half hour or longer. Be sure the
water level is at least two inches
above the antiventilation plate to
avoid overheating and water pump
damage.
7.
As
soon as possible, take the
outboard motor to an authorized
Honda Marine dealer for
inspection and service.
92
TECHNICAL INFORMATION
Serial Number Locations
Record the product identification
number and engine serial numbers in
the space provided on this page.
You
will need these numbers when
ordering parts, and when making
technical or warranty inquiries (p.
103
>.
TECHNICAL AND CONSUMER INFORMATION
PRODUCT
IDENTIFICATION
NUMBER
47
STERN BRACKET
The product identification number is
stamped on a plate attached on the
right stern bracket.
Product identification number:
ENGINE SERIAL NUMBER
The engine serial number is
stamped on the upper right side
of
the motor.
Engine serial number:
93
TECHNICAL AND CONSUMER INFORMATION
Oxygenated
Fuels
Some conventional gasolines are
being blended with alcohol or an
ether compound. These gasolines are
collectively referred to as oxygenated
fuels. To meet clean air standards,
some areas of the United States and
Canada use oxygenated fuels to help
reduce emissions.
If you use an oxygenated fuel, be
sure it is unleaded and meets the
minimum octane rating requirement.
Before using an oxygenated fuel, try
to confirm the fuel’s contents. Some
states/provinces require this
information to be posted on the pump.
The following
are
the EPA-approved
percentages of oxygenates:
ETHANOL: ethyl or grain alcohol;
10%
by volume.
You may
use
gasoline
containing
up
to
10%
ethanol by volume. Gasoline
containing ethanol may be marketed
under the name “Gasohol”.
MTBE: Methyl Tertiary Butyl Ether;
15%
by volume.
You may use gasoline containing up
to
15%
MTBE by volume.
METHANOL: methyl or wood
alcohol;
5%
by volume.
94
TECHNICAL AND CONSUMER INFORMATION
You may use gasoline containing up
to
5%
methanol by volume, as long
as it also contains cosolvents and
corrosion inhibitors to protect the
fuel system. Gasoline containing
more than
5%
methanol by volume
may cause starting and/or
performance problems. It may also
damage.meta1, rubber, and plastic
parts of your fuel system.
If you notice any undesirable
operating symptoms,
try
another
service station, or switch
to
another
brand of gasoline.
Fuel system damage or performance
problems resulting from the use of an
oxygenated fuel containing more
than the percentages of oxygenates
mentioned above are not covered
under warranty.
Battery
For complete information, refer to
the battery manufacture’s
instructions.
Minimum Requirements
12V-11OAH
95
TECHNICAL AND CONSUMER INFORMATION
Emission Control System
Information
Source
of
Emissions
The combustion process produces
carbon monoxide, oxides of nitrogen,
and hydrocarbons. Control of
hydrocarbons and oxides of nitrogen
is very important because, under
certain conditions, they react to form
photochemical smog when subjected
to sunlight. Carbon monoxide does
not react in the same way, but it is
toxic.
Honda utilizes lean carburetor
settings and other systems to reduce
the emissions
of
carbon monoxide,
oxides
of
nitrogen, and hydrocarbons.
The
US.
and California 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.
96
TECHNICAL AND CONSUMER INFORMATION
Problems That May Affect
Emissions
If you are aware of any of the
following symptoms, have your
engine inspected and repaired by
your servicing dealer.
0
Hard starting or stalling after
starting.
0
Rough idle.
0
Misfiring or backfiring under load.
0
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
genuine Honda parts whenever
you have maintenance done. These
original-design replacement parts are
manufactured to the same standards
as the original parts,
so
you can be
confident of their performance. The
use of replacement parts that are not
of the original design and quality
may impair the effectiveness of your
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.
55.
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.
97
TECHNICAL AND CONSUMER INFORMATION
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:
-1
0
0
t
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.
98
TECHNICAL AND CONSUMER INFORMATION
One Star
Low Emission
The one-star label identifies engines
that meet the Air Resources Board’s
2001 exhaust emission standards.
Engines meeting these standards
have
75% lower emissions than
conventional carbureted two-stroke
engines. These engines are equivalent
to the
U.S.
EPA’s
2006 standards for
marine engines.
Two Stars
Very Low Emission
The two-star label identifies engines
that meet the Air Resources Board’s
2004 exhaust emission standards.
Engines meeting these standards
have 20% lower emissions than One
Star-Low-Emission engines.
Three Stars
Ultra Low Emission
The three-star label identifies engines
that meet the Air Resources Board’s
2008 exhaust emission standards.
Engines meeting these standards
have 65% lower emissions than One
Star-Low-Emission engines.
Cleaner Watercraft
-
Get the Facts
1-800-END-SMOG
www.arb.ca.gov
99
TECHNICAL AND CONSUMER INFORMATION
Specifications
I
Mnnm
I
Rc')nnA
I
Description Code
75.8
in
65.7
in
1
70.9 in
Overall height
24.6
in
(625
mm)
Overall
width
36.2 in (920
mm)
Overall length
LA
1
XA
1
XCA
1
XXA
I
XXCA
Type
BAEJ
1
BAEJ
1
BAFJ
I
BAEJ
1
BAFJ
"I
LVUm
(1,670
mm)
(1,925
mm)
(1,800
mm)
Transom height
30.0
in
(762
mm)
25.0
in
(635
mm)
20.0
in
(508
Starter
system
Electric starter
Ignition system
Fully
transistorized, battery ignitoin
Lubrication system
Trochoid pump pressure lubrication
Specified oil
Engine: API standard (SG,
SH,
SJ)
SAE
IOW-30
Gear case:API standard
(GL-4/5)
SAE
90
outboard
motor
gear
oil
Gear case: 1
.OO
US
qt (0.95
Q
,0.84 Imp
Oil capacity Engine: 8.0 US qt (7.6
Q
,6.7 Imp
qt)
Fuel
pump Electric powered mechanical
Fuel
I
Automotive unleaded gasoline (86 pump
octane or higher)
Gear
change Forward-Neutral-Reverse (dog type)
Steering angle 30" right and left
Transom
anple
00-
20"
Honda outboards are power rated in accordance with
N"A
procedures and using the
ICOMIA
standard
28/23.
100
TECHNICAL AND CONSUMER INFORMATION
Specifications
MODEL
Description Code
Type
Overall length
Overall width
Overall height
Transom height
Weight
Rated power
Full
throttle range
Engine type
Displacement
Spark plug gap
(1,670 (1,800
rnrn)
(1,925
rnrn)
20.0
in
25.0
in
(635
rnrn)
30.0
in
(762
rnrn)
mrn)
589
Ibs
600
Ibs
(272 kg) 611
Ibs
(277 kg)
(267 kn)
Gear case:
1
.OO
US
qt
(0.95 !2,0.84
Imp
Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard
28/23.
101
TECHNICAL AND CONSUMER INFORMATION
CONSUMER INFORMATION
Honda Publications
These publications will give you
additional information for
maintaining and repairing your
outboard motor. You may order them
from your Honda marine dealer.
Shop
Manual
This manual covers complete
maintenance and overhaul procedures.
It is intended to be used by a skilled
technician.
Parts Catalog
This manual provides complete,
illustrated parts lists.
Customer Service Information
Honda Marine dealership personnel
are trained professionals. They
should be able to answer any
question you may have. If you
encounter a problem that your dealer
does not solve to your satisfaction,
please discuss it with the dealership’s
management. The Service Manager
or General Manager can help. Almost
all problems are solved in this way.
If
you are dissatisfied with the
decision made by the dealership’s
management, contact the Honda
Marine Customer Relations Office.
You can write:
American Honda
Motor
Co.,
Inc.
Marine Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, Georgia 30005-8847
Or telephone: (770) 497-6400
When you write or call, please give
us this information:
Model and serial numbers (p. 93
)
Name of the dealer who sold the
outboard motor to you
Name and address of the dealer
who services your outboard motor
Date of purchase
Your name, address, and telephone
number
A detailed description of the
problem
103
INDEX
Alternator (ACG) Indicator
............................................
28
Anodes
............................................................................ 31
ARE YOU READY TO GET UNDER WAY
?
32
Replacement 73
Battery
............................................................................
95
BATTERY WILL NOT CHARGE AND
ELECTRIC STARTER WILL NOT OPERATE
......
87
BEFORE OPERATION
................................................. 32
...............................................................
..........
BREAK-IN PROCEDURE
............................................
34
Common Controls
..........................................................
25
COMPONENT AND CONTROL LOCATIONS
.........
11
CONSUMER INFORMATION
..................................
103
CONTROLS
...................................................................
15
CONTROLS AND FEATURE IDENTIFICATION
CODES
.......................................................................
10
CONTROLS AND FEATURES
...................................
10
Cooling System Indicator
...............................................
30
CRUISING
.....................................................................
48
Customer Service Information
.....................................
103
Emission Control System Information
.......................... 96
Engine
Cover
Latch
.......................................................................
27
Lock Lever Adjustment
.........................................
59
Lock Lever Bracket Adjustment ............................ 59
REMOVAL AND INSTALLATION
....................
58
Change
....................................................................
60
Level Check
...........................................................
60
Recommendations
..................................................
62
Oil
104
INDEX
Fast Idle Lever
................................................................
18
Fuel
PRIMING
...................................................................
35
Priming Bulb
.............................................................. 3
1
RECOMMENDATIONS
...........................................
68
Pump Filter Inspection and Replacement
.................. 69
Gear Oil Level Check
.....................................................
63
GearshifdTrottle Control Lever
Panel-Mount Type
......................................................
20
Side-Mount Type
.......................................................
16
GEARSHIFTING AND THROTTLE OPERATION 45
Top-Mount Type 23
Panel-Mount Type
......................................................
46
Side-Mount Type
.......................................................
45
Top-Mount Type
........................................................
46
HOISTING THE OUTBOARD MOTOR
.....................
78
........................................................
...
Ignition Switch
Panel-Mount Type
......................................................
i8
Side-Mount Type
.......................................................
15
Top-Mount Type
........................................................
22
IMPORTANT SAFETY INFORMATION
..................... 7
INDICATORS
................................................................
28
INSTRUMENTS
............................................................
27
IS
YOUR OUTBOARD MOTOR
READY TO GO
?
.....................................................
32
Lubrication Points
.......................................................... 63
MAINTENANCE SAFETY
..........................................
53
MAINTENANCE SCHEDULE
....................................
55
MOORING. BEACHING. LAUNCHING .................... 50
105
INDEX
Oil Pressue Indicator
......................................................
29
OIL PRESSURE INDICATOR LIGHT GOES
OFF AND ENGINE SPEED
IS
LIMITED
...............
89
OPERATION
.................................................................
34
OTHER FEATURES
.....................................................
3
1
OUTBOARD MOTOR SAFETY
....................................
7
Overheating Indicator
.....................................................
29
OVERHEATING INDICATOR LIGHT COMES
ON AND ENGINE SPEED IS LIMITED
................. 90
Overrev Limiter
..............................................................
3 1
Oxygenated Fuels
...........................................................
94
Power Tilt Switch
...........................................................
26
Power TridTilt Switch
.................................................
25
Programmed Fuel Injection (PGM-FI) Indicator ........... 28
Propeller Replacement
...................................................
74
REMOVAL FROM STORAGE
....................................
80
SAFE OPERATING PRECAUTIONS
.........................
34
SAFETY LABEL LOCATIONS
.....................................
9
Serial Number Locations
................................................ 93
SERVICING YOUR OUTBOARD MOTOR
...............
52
SHALLOW WATER OPERATIONS
...........................
50
Spark Plug Service
.........................................................
64
Specifications
...............................................................
100
Star Label
.......................................................................
98
STARTING THE ENGINE
...........................................
36
Panel-Mount Type
...................................................... 39
Side-Mount Type
....................................................... 36
STEERING
.....................................................................
47
STOPPING THE ENGINE
............................................
43
Emergency Engine Stopping
......................................
43
Normal Engine Stopping
............................................
44
STORAGE
.....................................................................
75
STORAGE PRECAUTIONS
.........................................
79
STORAGE PREPARATION
.........................................
75
Cleaning and Flushing
...............................................
75
Engine
oil
...................................................................
78
Fuel
.............................................................................
77
SUBMERGED MOTOR
................................................
91
Switch Clip and Emergency Stop Switch
Top-Mount Type
........................................................
41
Panel-Mount Type
......................................................
19
Side-Mount Type
.......................................................
16
Top-Mount Type
........................................................
22
106
Tachometer (optional equipment)
..................................
28
TAKING CARE OF UNEXPECTED PROBLEMS
.....
82
TECHNICAL AND CONSUMER INFORMATION ... 93
TECHNICAL INFORMATION
....................................
93
THE IMPORTANCE
OF
MAINTENANCE
................
52
Throttle Button
Panel-Mount Type
......................................................
20
Top-Mount Type ........................................................ 23
Tilt Lock Lever
...............................................................
26
TRANSPORTING
.........................................................
81
ON BOAT
..............................................................
81
FROM BOAT
........................................................
81
Trim Meter (optional equipment)
..................................
27
Trim Tab
.........................................................................
27
TRIM TAB ADJUSTMENT
.........................................
57
Water Separator
..............................................................
71
WIRING DIAGRAMS
.........................
Inside Back Cover
TOOL KIT (optional equipment)
...................................
54
WITH OUTBOARD MOTOR INSTALLED
WITH OUTBOARD MOTOR REMOVED
107
t
I
f
I
I-
I
I
I
I
II
I
4
3:
i
i
-u-
I II
i6
1
m
m
I
a
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I
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