Honda BF40 - 50 Outboard Engines 40 and 50 hp 4 Stroke User Manual

pnuew

-rUEkJlU

S,&3UMO

vos/vowscda

YCINOH

Thank you for purchasing a Honda

Outboard Motor.

This manuul describes the operation

and maintenance of the Honda

BF3SA

and

BF4OA and BFWA Out-

board Motors.

All information in this publication is

hased

the latest product informa-

tion available at the time of printing.

Honda Motor Co.. Ltd. reserves the

right to make changes at any time

without notice and without incurring

any obligation.

No part of this publication may be

reproduced without written

permission.

This manual should be considered a

permanent part of the Outboard Motor

and it must stay with the Outboard

Motor if resold.

READ THIS OWNER’S MANUAL

CAREFULLY. Pay special attention to

these symbols and any instructions

that follow.

You WILL be

KILLED or SERIOUSLY HURT

if you don’t follow instructions.

B You CAN be

KILLED or SERIOUSLY HURT

if you don’t follow instructions.

You CAN be HURT

if you don’t follow instructions.

NOTICE 1 Your outboard motor

or other property can be damaged

if you don’t follow instructions.

Honda Outboard Motors are designed

to give safe and dependable service if

operated according to instructions.

Operating this Outboard Motor

requires special effort on your part to

ensure your-safety and the safety of

others.

Careless operation

or misuse may cause injury or

property damage. Read and

understand this owner’s manual

before operating the Outboard

Motor.

If a problem should arise, or if you

have any questions about your

Outboard Motor, see an authorized

Honda Marine dealer.

HONDA MOTOR CO., LTD. 1994,

TYPES OF HONDA BF35A/40A/5OA OUTBOARD MOTORS

It may hc necessary to rcfcr to this chart for reference purposes when reading this manual.

TYPE CODE (example)

L R T T = Power Trimmilt

R = Remote Control H = Tiller Handle

TT-II

X = Extra Long Shaft L = Long Shaft

IDENTIFICATION NUMBERS

RIGHT STERN BRACKET

, ,-in,

PRODUCT IDEliTiFICATION NUMBER

Record the Product Identification

Number (P.I.N.)

and the Engine Serial

Number for your reference. Refer to

the Product Identification Number

when

ordering parts, and when mak-

ing technical or warranty inquiries

(see page 101).

STARTER MOTOR

- -\

The Product Identification Number is

stamped on a plate and attached to the

right stern bracket. The Engine Serial

Number is stamped on the cylinder

block under the starter motor which is

located in the front of the engine.

Product identification number:

Engine serial number:

CONTENTS

1. SAFETY

SAFETY LABELS..

................................................... 6

SAFETY INFORMATION

........................................ 7

2. COMPONENT IDENTIFICATION

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

3. CONTROLS

TILLER HANDLE TYPE

Engine Start Button

.................................................... 1 I

Shift Lever..

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

Choke Knob.. ..............................................................

1 I

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

Throttle Opening Indicator

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

Throttle Friction Knob

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

Engine Stop Switch

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

Emergency Stop Switch

Lanyard

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

Oil Pressure Indicator Light

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

Overheat Indicator Light

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

REMOTE CONTROL TYPE

Remote Control Lever

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

Neutral Release Lever

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

Ignition Switch

........................................................... I6

Emergency Stop Switch

Lanyard

............................... I7

Choke/Fast Idle Lever

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

Manual Choke Knob

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

Oil Pressure Indicator Light/Buzzer..

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

Overheat Indicator Light/Buzzer

................................ I9

REMOTE CONTROL & PQWER TRIM/TILT TYPE

Power Trim/Tilt Switch (remote control lever)

.......... 20

Power Tilt Switch (motor pan)

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

2 I

Trim Meter

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

Tachometer

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

2 I

Manual Relief Valve

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

GAS ASSISTED TILT TYPE

Tilt Lever

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

CONTROLS & INSTRUMENTS (common)

Tilt Lock

Lever.. .........................................................

Trim Tab..

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

Anode Metal

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

Cooling

System

Indicator..

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

Water

Intakes..

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

Transom Angle Adjusting Rod

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

Fuel Cap/Gauge/Vent

Knob

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

Over-Rev Limiter

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

4. PRE-OPERATION CHECKS

Engine Cover Removal/Installation

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

Engine

Oil

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

Fuel Level..

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

Fuel Recommendations

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

3 1

Oxygenated Fuels

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

Propeller and Cotter pin

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

Steering Friction Adjustment (common).

................... 33

Remote Control

Friction

Adjustment

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

Other Checks

Stern

bracket

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

Tool Kit

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

Anodes

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

5. STARTING THE ENGINE

Fuel Tank and Vent Knob

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

CONTENTS

Fuel Line Connection

................................................. 35

STARTING THE ENGINE (TILLER HANDLE TYPE).

... 37

STARTING THE ENGINE (REMOTE CONTROL TYPE). ...

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

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

6. OPERATION

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

TILLER HANDLE TYPE

Gear Shifting

......................................................... 5 1

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

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

REMOTE CONTROL TYPE

Gear Shifting

......................................................... 53

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

Tilting motor

GAS ASSISTED TILT TYPE..

............................. 55

POWER TRIM/TILT TYPE

................................. 58

POWER TRIM/TILT TYPE

Trim Meter .............................................................

Power Tilt Switch (Motor Pan)

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

Manual Relief Valve..

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

Tilt Lock Lever

...................................................... 6 1

Trim Tab Adjustment

................................................. 62

MOTOR PROTECTION SYSTEM

Engine Oil Pressure and

Overheat Warning

System.. ................................... 63

Over-Rev Limiter

.................................................. 65

Power Trim Wgning System

................................ 65

Anodes ................................................................... 66

Shallow Water Operation ...................................... 67

High Altitude Operation ........................................ 68

7. STOPPING THE ENGINE

TILLER HANDLE TYPE ..................................... 69

REMOTE CONTROL TYPE ................................ 7 1

8. TRANSPORTING

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

9. CLEANING AND FLUSHING

................................. 73

10. MAINTENANCE..

..................................................... 75

Tool Kit and Spare Parts.. ...................................... 76

MAINTENANCE SCHEDULE ............................ 77

Engine Oil .............................................................. 79

Gear Oil ................................................................. 8 I

Spark Plugs ............................................................ 83

Battery (not included). ........................................... 84

Lubrication ............................................................ 86

Engine Fuel Filter .................................................. 87

Fuel Tank and Filter .............................................. 89

Fuse Replacement.. ................................................ 90

Propeller ................................................................ 9 1

Submerged Motor .................................................. 92

I 1. STORAGE

................................................................. 94

12. TROUBLESHOOTING

............................................. 96

13. SPECIFICATIONS

.................................................... 98

14. WARRANTY

SERVICE ........................................... 101

15. WIRING

DIAGRAM ................................................. 102

. 16. INDEX

....................................................................... I05

1. SAFETY

SAFETYLABELS

These labels are in the locations

show& They warn you of potential

hazards that could seriously injure

you. Read these labels carefully.

EXTREMELY

FLAMMABLE

FUI USE As A lwu1 FIEI. ma.” -#+A” omT,IN EM UlTl twa coparm

1. SAFETY

SAFETY INFORMATION

For your safety and the safety of oth-

ers, pay special attention to these pre-

cautions.

Operator Responsibility

-Know how to stop the engine

quickly in case of emergency.

Understand the use of all controls.

Do not exceed the boat manufactur-

er’s power recommendation, and be

sure that the outboard motor is

properly mounted.

Never permit anyone to operate the

outboard motor without proper

instruction.

Stop the engine immediately if any

one falls overboard.

Do not run the motor while the

boat is near anyone in the water.

Attach the emergency stop switch

lanyard securely to the operator.

not remove the engine cover

while the engine is running.

Before operating the outboard

.motor, familiarize yourself with all

laws and regulations relating to

boating and the use of outboard

motors.

Do not attempt to modify the out-

board motor.

Always wear PERSONAL

FLOTATION DEVICE (PFD) when

on board.

Do not remove any guards, labels,

shields, covers or safety devices;

they are installed for your safety.

Fire and Burn Hazards

Gasoline is extremely flammable, and

gasoline vapor can explode. Use

extreme care when handling gasoline.

Remove the fuel tank from the boat

for refueling.

Refuel in a well-ventilated area

with the engine stopped. Keep

flames and sparks away, and do not

smoke in the area.

Refuel carefully to avoid spilling

fuel. Avoid overfilling the fuel tank

(there should be no fuel in the filler

neck). After refueling, tighten the

filler cap securely. If any fuel is

spilled, make sure the area is dry

before starting the engine.

2. COMPONENT IDENTIFICATION (TILLER HANDLE TYPE)

THROTTLE GRIP

FUEL LINE

CONNECTOR

ENGINE COVER

OIL FILLER CAP

OIL LEVEL

GEAR SHIFT LEVER

LEVER

I IP

STERN

IV,

ENGINE OIL

U.-I

[ ANTI-VENTILATION

TRANSOM

ANGLE

GEAR OIL

LEVEL PLUG

(ANODE METAL)

PROPELLER

THROTTLE

FRICTION K

ENGINE START

BUTTON

TILT LEVER

WATER INTAKE

OIL

.NOB

.---

PRESSURE INDICATOR LIGHT

OVERHEAT

INDICATOR

LIGHT

CHOKE KNOB

/ I

EMERGENCY

STOP SWITCH

EMERGENCY

LANYARD

STOP SWITCH

CLIP

SPARE EMERGENCY

STOP SWITCH CLIP

GEAR OIL DRAIN PLUG

2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE)

ENGINE

COVER

FUEL LINE

CONNECTOR

POWER TILT

SWITCH

ENGINE OIL

M ANUA<

DRAIN BOLT

ACCESS COVER

RELIEF VALV

OIL FI$LER CAP

OIL LEVEL

DIPSTIC

POWER TRIM/TILT

SWITCH

NEUTRAL

Fgi;fzL~gi;g

OVERHEAT

“DICATOR In

LIGHT

COOLING

LEVEK

SYSTEM

INDICATOR

GEAR OIL

LEVEL PL

ETAL)

GEAR OIL

EXHAUST PORT

DRAIN PLUG

PROPELLER

WASH PLUG

(Flush plug)

CHOKE/FAST

IDLE LEVER

STOP SWITCH CL1

EMERGENCY STOP

ENGINE STOP

SWITCH LANYARD

WATER INTAKE

EMERGENCY STOP

SWITCH CLIP

2. COMPONENT IDENTIFICATION

VENT KNOB

FUEL GAUGE

FUEL CAP

FUEL T

FUEi

FUEL HOSE CONNECTOR

PRIMER BULB

(FEMALE)

POWER TRIM/TILT TYPES

TACHOMETER

TRIM METER

3. CONTROLS (TILLER HANDLE TYPE)

Engine Start Button

(reverse) N

ENdINE START

BUTTON

Move the gearshift lever to the N

(neutral) position before starting. The

engine will not start unless the

gearshift lever is in the N (neutral)

position.

Shift Lever

(reveZse)

SHIti LEVER

There are three gearshift lever posi-

tions.

F (forward): The boat moves forward.

N (neutral): The transmission gears

are disengaged from the

engine.

R (reverse): The boat reverses.

Choke Knob

CHOti KNOB

When the engine is cold, pull the

choke knob. A rich fuel mixture is

provided to the engine by pulling the

choke knob.

3. CONTROLS (TILLER HANIDLE TYPE)

Throttle Grip

THRO’ITLE GRIP

Turn the grip clockwise or counter-

clocktiise to adjust the engine speed.

Turning the grip in the direction

shown by the arrow increases engine

speed.

Throttle Opening Indicator

THROTTLE OPENING INDICATOR

The curve on the &tip indicates throttle

opening.

Throttle Friction Knob

THROTI’LE FRICTION KNO

RELEASE

Use the throttle friction knob to set the

throttle grip at a certain position while

cruising. Turning the friction knob

clockwise sets the throttle grip, and it

is released by turning the friction knob

counterclockwise.

3. CONTROLS (TILLER HANDLE TYPE)

Engine Stop Switch

ENGINE STOP SWITCH

Push the engine stop switch to stop the

engine.

Emergency Stop Switch Lanyard

EMERGENCY STOP SWITCH CLIP

The emergency stop switch lanyard is

provided to stop the engine immedi-

ately in the event the operator should

fall overboard or away from the con-

trols.

The emergency stop switch clip must

be engaged with the engine stop

switch or the engine will not start.

When the emergency stop switch clip

becomes disengaged with the engine

stop switch the engine will stop imme-

diately.

ENGINE STOP

SWITCH

EMERGENCY STOP SWITCH LANYARD

Attach the emergency stop switch lan-

yard securely to the operator when

operating the outboard motor.

3. CONTROLS (TILLER HANDLE TYPE)

SPARE EMERGENCY

,STOP SWITCH CLIP

A spare emergency stop switch clip is

provided near the engine stop switch.

Oil Pressure Indicator Light

OIL PRESSURE INDICATOR LIGHT

The green oil pressure indicator light

is normally ON when the outboard

motor is running.

When the engine oil level is low or the

engine lubrication system is faulty, the

green oil pressure indicator light turns

OFF and the engine speed decreases

gradually.

Overheat Indicator Light

OVERHEAT INDICATOR LIGHT

When the engine cooling system is

faulty, the red overheat indicator light

turns ON and the engine speed

decreases gradually.

3. CONTROLS (REMOTE CONTROL TYPE)

Remote Control Lever

The remote control lever controls gear

selection and throttle opening posi-

tions.

It is necessary to pull up the neutral

release lever to operate the remote

control lever.

THROm

(NEUiRAL, R

REMOTE CONTROL LEVER

F (forward):

Moving the lever to the F position

(approximately 30’ from the N

position) will engage the forward

gear. Moving the lever further from

the F position will increase the

throttle opening and the boat for-

ward speed.

N (neutral):

The engine idles and the transmis-

sion gears are disengaged.

R (reverse):

Moving the lever to the R position

(approximately 30” from the N

position) will engage the reverse

gear. Moving the lever furthen into

the R position will increase the

throttle opening and the boat

reverse speed.

3. CONTROLS (REMOTE CONTROL TYPE)

Neutral Release Lever

The neutral release lever is on the

remote control lever to prevent an

accidental gear engagement.

The remote control lever will not

engage forward or reverse gear unless

the neutral release lever is pulled up.

Ignition Switch

+ ON

START

The remote control box is equipped

with a key type ignition switch.

Key positions:

START

To activate the starter motor and start

the engine.

(the remote control lever

must be in the neutral position)

To run the engine after starting (the

battery will discharge if the key is

left in this positidn with the engine

not running).

OFF

To stop the engine (IGNITION

OFF).

To prevent the battery from dis-

charging, keep the key in the OFF

position when the engine is not run-

ning.

3. CONTROLS (REMOTE CONTROL TYPE)

Emergency Stop Switch Lanyard

The emergency stop switch lanyard is

provided to stop the engine immedi-

ately in the event the operator should

fall overboard or away from the con-

trols.

The emergency stop switch clip must

be engaged with the emergency engine

stop switch or the engine will not start.

When the emergency stop switch clip

becomes disengaged from the emer-

gency engine stop switch the engine

will stop immediately.

The emergency engine stop switch

should not he used to normally stop

the engine. Use the ignition switch to

normally stop the engine.

Attach the emergency stop switch lan-

yard securely to the operator when

operating the outboard motor.

SPA’RE EMERGENCY

STOP SWITCH CLIP

A spare emergency stop switch clip is

provided on the remote control box.

3. CONTROLS (REMOTE CONTROL TYPE)

Choke/Fast Idle

Lever

f’-J CHOKE

XIMUM FAST IDLE

OWEST POSITION

&AST

The choke/fast idle lever provides two

functions:

1. Electric choke solenoid activation

for easy engine start up.

2. Engine fast idle.

The choke/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 choke/fast

idle lever is in the lowest position.

IDLE LEVER

Lift and hold the choke/fast idle lever

up fully, this will provide a rich fuel

mixture and the correct fast idle.

Gradually lower the choke/fast idle

lever to the lowest position to decrease

the choke and fast idle.

Manual Choke Knob

CHOKE KNOB

A manual choke knob is provided on

the right side of the motor which can

be used in the event the battery is dis-

charged. Pull the manual choke knob,

and a rich fuel mixture will be provid-

ed to the engine.

3. CONTROLS (REMOTE CONTROL TYPE)

Oil Pressure Indicator Light/Buzzer

The green oil pressure indicator light

turns OFF and the buzzer sounds

when the oil level is low and/or the

engine lubrication system is faulty.

The engine speed slows down gradual-

ly-

Overheat Indicator Light/Buzzer

The red overheat indicator light turns

ON and the buzzer sounds when the

engine cooling system is faulty. The

engine speed Slows down gradually.

3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)

Power ‘l’kim/Tilt Switch (remote

control lever)

Power Tkim

Press the power trim/tilt switch on the

remote control lever to adjust the

motor trim angle of 0” to 20” to main-

tain proper boat trim. The power

trim/tilt switch located on the remote

control lever can be operated while the

boat is under way or while stopped.

using the power trim/tilt switch the

operator can change the trim angle of

the motor to achieve maximum boat

acceleration, speed, stability and

maintain optimum fuel consumption.

Power Tilt

Press the power trim/tilt switch on the

remote control lever to adjust the

motor tilt angle of 20” to 60’.

using the power trim/tilt switch the

operator can change the tilt angle of

the motor for shallow water operation,

beaching, launching from a trailer, or

mooring.

pi6Tzq

Excessive trim/tilt angle

during operation can cause the pro-

peller to raise out of the water and

cause propeller ventilation and

engine over-revving. Excessive

trim/tilt angle can also damage the

water pump.

XRTA type outboard

Power Trim

Do not trim

this engine when you are

using a large amount of throttle

opening. If you do try to trim the en-

gine, under certain conditions, pro-

peller thrust may override the power

trim hydraulics and cause the engine

to return to the transom angle adjust-

ing rod. (Full “in” position)

Power Tilt

Press the power tilt switch on the

remote control lever to adjust the

motor tilt angle of 20” to 60”.

By using the power tilt switch the op-

erator can change the tilt angle of the

motor for shallow water operation,

beaching, launching from a trailer, or

mooring.

3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)

Power Tilt Switch (motor pan)

POWER TILT SWITCH

The power tilt switch located on the

motor pan is a conveyance switch for

tilting the motor for trailering, or pre-

forming outboard maintenance. This

power tilt switch should only be oper-

ated with the boat being stopped and

motor off.

Trim Meter

TRIM METER

The trim meter has a range of 0’ to 20”

and indicates the trim angle of the out-

board motor. Refer to the trim ‘meter

when using the power trim/tilt switch

to achieve proper boat performance.

Tachometer

TACHOMETER

The tachometer shows the approxi-

mate engine speed in revolutions per

minute. Refer to the tachometer when

using the power trim/tilt switch to

achieve proper boat and motor perfor-

mance.

3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)

Manual Relief Valve

If the power trim/tilt switch will not

tilt the outboard motor, the motor can

be manually tilted up or down by

opening the manual relief valve. To

tilt the outboard motor manually, turn

the manual valve under the left stem

bracket no more than 1 or 2 turns

counterclockwise using a screw driver.

After tilting the motor, turn the manual

relief valve clockwise securely.

The manual relief valve must be tight-

ened securely before operating the

motor or the motor could tilt up when

operating in reverse.

LEFT STERN BRACKET

MANUAL

WER (To WI-)

Rx)

MANUAL-RELIEF VALVE

Do not turn this -screw. If this screw

is turned hydraulic oil will bleed out

of the power trim/tilt system. Should

this happen it will be necessary to

consult your authorized Honda

Marine dealer and have the system

refilled.

Tilt Lever (GAS ASSISTED

TYPE)

Moving the tilt lever to the FREE

position allows the motor to be tilt-

ed and moving the tilt lever to the

LOCK

position

locks the

motor in the

desired position.

Use

the tilt

lever to

temporarily tilt the motor when the

boat is operating in shallow water, or

mooring in shallow water. The tilt

lever must be in the LOCK position

before operating the motor or the

motor could tilt up when operating in

reverse.

3. CONTROLS & INSTRUMENTS (common)

Tilt Lock Lever

Use the tilt lock lever to hold the

motor in the highest tilt position

when the boat is moored for a long

time.

Tilt the motor up as far as it will go

then move the tilt lock lever into the

lock position and gently lower the

motor.

Trim Tab

PROPELLER

When making a turn, if an unequal

amount of effort is required to turn

the steering wheel or tiller handle

right or left, adjust the trim tab so

that an equal amount of effort is

required.

TAB

Distribute the load evenly in the boat

and run the boat in straight course at

full throttle. Slightly turn the steering

wheel or tiller handle for both right

and left turns to determine if an equal

amount of effort is required. If adjust-

ment is necessary loosen the tighten-

ing bolt and turn the trim tab right or

left. Make small adjustments at a

time and retest. Incorrect trim tab

adjustment can cause adverse steering.

The trim tab also functions as an anode.

3. CONTROLS d!k INSTRUMENTS (common)

Anode Metal

Y----l

The anodes are made from a sacrificial

material which helps to protect the

outboard motor from corrosion.

ANODiX

(stem

bracket)

NOTICE]

Painting or coating the

anodes will lead to rust and corro-

sion damage to the outboard motor.

Cooling System Indicator

C~~'LIN~ SYSTEM

INDICATOR

The cooling system is monitored here

to make sure cooling water is circulat-

ing through the engine.

3. CONTROLS & INSTRUMENTS (common)

Water Intakes

WATER INTAKES

The engine cooling water is drawn

into the water pump through these

water intakes.

3. CONTROLS & INSTRUMENTS (common)

Transom Angle Adjusting Rod

TRANSOM ANGLE ADJUSTING ROD

The transom angle adjusting rod is

used to adjust the motor angle to

achieve the correct boat trim. There

are 5 adjustment holes located in the

stem bracket.

Push in and turn the transom angle

adjusting rod up to remove. To install

insert into the proper hole and turn

down to lock. After installation pull

the transom angle adjusting rod out-

. ward to be sure it is locked in place.

Start with the transom angle adjusting

rod in the hole closest to the boat tran-

TRANSOM ANGLE

ADJUSTING ROD

UNLOCKED

POSITION

‘ItI LOCK

LOCKED POSITION

som, lower the motor and operate the

boat at full speed. If the bow is exces-

sively low stop the boat. Tilt the motor

up and raise the transom angle adjust-

ing rod one more hole away from the

transom and retest. The optimum boat

trim is when the boat is parallel with

the water.. The transom angle adjust-

ing rod stops the motors forward

movement.

The motor should never be operated

with the transom angle adjusting rod

removed.

3. CONTROLS & INSTRUMENTS (common)

Fuel Cap/Gauge/Vent Knob

VENT KNOB

GAUGk FUEL FiLLEIi CkP

The fuel gauge is part of the fuel cap.

The fuel cap vent knob controls air

entering and leaving the fuel tank.

When refilling the fuel tank, turn the

vent knob counterclockwise to the

open position and remove the fuel cap.

Before transporting, storing or refill-

ing the fuel tank inspect the condition

of the fuel cap gasket and replace if

necessary.

Before transporting or storing the fuel

tank turn the vent knob fully clock-

wise to the closed position.

Anytime the fuel tank is in the boat

with the vent knob closed, discon-

nect the fuel hose connector from

the outboard motor (refer to page

35).

extremely flammable, and gaso-

line vapor can explode, causing

serious injury or death. Do not

smoke or allow flames or sparks

in your working area. KEEP

OUT OF REACH OF CHILDREN.

Over-Rev Limiter

This outboard motor is equipped with

an engine over-rev limiter which limits

the maximum engine rpm. This over-

rev limiter protects the engine from

mechanical damage.

The over-rev limiter may be activated

by putting the propeller in a light load

condition or propeller ventilation.

When the over-rev limiter is activated

the engine rpm will become unstable

or erratic. Should this occur reduce the

throttle opening and wait for the

engine r-pm to stabilize then increase

the throttle opening.

On the power trim/tilt type motors lower

the trim angle on high speed turns to re-

duce the possibility of propeller ventila-

tion.

Engine Cover Removal/InstalIation

(FRONT) (WAR)

ENGINE COVER

LATCHES

To remove, release the front and rear

engine cover latches and remove the

engine cover.

To install, position the engine cover

ovei the engine and hook and lpck the

front and rear latches.

4. PRE-OPERATION CHECKS

Engine Oil

Engine oil is a major factor affecting

engine performance and service life.

-1 Running the engine with

insufficient oil can cause serious

engine damage.

Recommended oil

Use high-detergent, premium quality

4-stroke engine oil, certified to meet

or exceed U.S. automobile manufac-

tures’ requirements for American

Petroleum Institute (API) Service

Classification SG, SH. Engine oils

classified SG, SH will show these

designations on the container.

Select the appropriate viscosity for the

average temperature in your area.

SAE low-30 is recommended for gen-

eral, all-temperature use (BF35A).

SAE 5 W-30 is recommended for gen-

eral, all-temperature use (BF40A/SOA).

API Service Grade: Use a Fuel

Efficient SG, SH oil.

NOTE: This oil is usually identified

by words such as: “Energy Conserving

II.” “Gas Saving, ” “Fuel Saving,” etc.

Inspection

1. Position the outboard motor verti-

cally, and remove the engine cover.

2. Remove the oil level dipstick and

wipe with a clean rag.

3. Reinsert the dipstick all the way in,

then pull it out and read the level. If

the oil registers near or below the

lower level mark, remove the oil

filler cap and fill to the upper level

mark with the recommended oil.

NOTICE Do not overfill. Excessive

oil can damage the engine.

4. Reinstall the oil tiller cap and tight-

en securely.

5. Install the engine cover and lock it

securely.

When the engine oil is contaminated or

discolored, replace with fresh engine oil

(refer to page 79 for oil capacity,

replacement interval and procedure).

4. PRE-OE’ERATION CHECKS

Fuel Level

FUELGhGE

Check the fuel gauge and refill the

tank to the SAFE FILL level mark if

necessary.

Fuel tank capacity : 6.6 US gal. (25 lit)

B Gasoline is

extremely flammable, arnd gaso-

line vapor can explode, causing

serious injury or death. Do not

smoke or allow flames or sparks

in your working area. KEEP

OUT OF REACH OF CHILDREN.

VENTKNOB

FUELCAP

Refilling

Remove the fuel tank from the boat

for refilling. Turn the vent knob coun-

terclockwise to the open position and

remove the fuel cap.

Refuel in a well-ventilated area. Fill

the fuel tank up to the SAFE FILL

level mark only. Inspect the condition

of the fuel cap gasket and replace if

necessary.

After refilling, install and tighten the

fuel cap securely. Turn the vent knob

clockwise to the closed position.

Return the fuel tank to the boat.

4. PRE-OPERATION CHECKS

Fuel Recommendations

Use unleaded gasoline with a pump octane rating of 86

or higher.

This engine is designed 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/gaso-

line mixture. Avoid getting dirt or water in the fuel tank.

Occasionally you may hear light “spark knock” or “ping-

ing” (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 Ma-

rine or Honda Outboard Motor dealer.

1-1 Running the engine with persistent spark

knock or pinging can cause engine damage.

Running the engine with persistent spark knock or ping-

ing is misuse, and the Distributor’s Limited Warranty

does not cover parts damaged by misuse.

4. PRE-OPERATION CHECKS

Oxygenated Fuels

Some conventional gasolines are being blended with alco-

hol or an ether compound. These gasolines are collec-

tively 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 oxy-

genates:

ETHANOL -

(ethyl or grain alcohol) 10% by volume

You may use gasoline containing up to

10% ethanol by volume. Gasoline con-

taining ethanol may be marketed under

the name “Gasohol”.

MTBE - (Methyl Tertiary Butyl Ether) 15% by volume

You may use gasoline containing up to

15% MTBE by volume.

METHANOL

-(methyl or wood alcohol) 5% by volume

You may use gasoline containing up to

5% methanol by volume, as long as it

also contains cosolvents and corrosion

inhibitors to protect the fuel system.

Gasoline containing more than 5%

methanol by volume may cause starting

and/or performance problems. It may

also damage metal, rubber, and plastic

parts of your fuel system.

If you notice any undesirable operating symptoms, try an-

other service station, or switch to another brand of gaso-

line.

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.

4. PRE-OPERATION CHECKS

Propeller and Cotter pin

COTTERPIN /

(stainless steel)

Propeller

Check the propeller blades for

damage, wear or deformation and

replace if necessary. Never operate the

outboard motor with a damaged pro-

peller.

Carrying a spare propeller, propeller

nuts, and cotter pins are common prac-

tice. If the propeller is damaged and

no spare propeller is available consult

an authorized Honda Marine dealer.

(Refer to page 91 for propeller change

information)

PROPELLER

Cotter Pin

Check the cotter pin for damage and

correct installation. If the cotter pin

needs replacement use only a new

genuine Honda stainless steel cotter

pin.

Steering Friction Adjustment

(common)

TO DECREASE

STEERING

\ e\,< FRICTION

Operate the steering wheel or tiller

handle right and left and check for the

amount of drag felt.

Adjust the steering friction adjuster so

that a slight amount of drag is felt. The

steering should move smoothly and

freely.

4. PRE-OPERATION CHECKS

Remote Contml Friction

Adjustment

TO INCREASE

FRICTION

Operate the remote control lever into

forward and reverse gears and check

for the amount of drag felt.

Adjust the remote control friction

adjuster so that a slight amount of drag

is felt. The remote control lever should

move smoothly and freely.

Check the followihg items:

1. The fuel hose for kinking, collaps-

ing or loose connections.

2. The stem bracket for damage and

mounting bolts for proper torque.

3. The tool kit contents. Compare your

tool kit contents against the tool kit

illustration above. Replace any

missing items.

The anodes for damage, looseness

or excessive corrosion.

The anodes help to protect the out-

board motor from corrosion any time

they are exposed directly to the water.

Other Checks

PUT SCREWDRIVER

I II

PLIRRS

YHILLIPS

‘ 0 -)

SCREWDRIVER SCRRWDRIVRR

HANDLE

nmL BAG

011. CHECK

SCREWDRIVER

#”

II I I9 mm WRENCH

Replace anodes when they are visibly

reduced in size or crumble easily.

w Painting or coating the

anodes will lead to rust and corro-

sion damage to the outboard motor.

The following materials should be

kept with the boat:

1. Owner’s Manual.

Tool Kit.

3. Spare engine oil, spark plugs, pro-

peller, propeller cotter pins and nut.

4. Required information regarding

boating laws and regulations.

5. STARTING THE ENGINE

Fuel Tank and Vent Knob

VENT KNOB

The fuel tank must be properly se-

cured in the boat. This will protect

the fuel tank from mechanical dam-

age caused by the fuel tank shifting.

The fuel tank must be in a well venti-

lated area to reduce the chance of a

gasoline vapo; explosion. Avoid di-

rect sunlight on the fuel tank.

Due to the fuel pump capacity, do

not place the fuel tank more than 6

feet away from the motor or lower

than 3 feet below the outboard end

fuel hose connector.

1. Open the fuel tank vent by turn-

ing the vent knob at least 2 or 3

turns counterclockwise. Allow

the air pressure inside the fuel

tank to equalize with the outside

air. With the vent open, air can en-

ter the fuel tank to displace the

fuel as the fuel level goes down.

2. Remove the fuel cap and inspect

the condition of the fuel cap and

gasket. Replace the fuel cap or

gasket if they are cracked,

dam-

aged or leak fuel.

Fuel Line Connection

FUEL HOSE CONNECTOR

(FUEL TANK END)\

Inspect the fuel hose, and the O-ring

seals in the fuel hose connectors. Re-

palce the fuel hose, or fuel hose con-

nectors if they are cracked, damaged

or leak fuel. Be sure the fuel hose is

not kinked.

1. Connect the fuel hose connector

to the fuel tank. Be sure the fuel

hose connector is securely

snapped in place.

5. STARTING THE ENGINE

FUEL HOSE CONNECTOR

(OUTBOARD END)

2. Connect the fuel hose connector

to the outboard motor. Install the

outboard end fuel hose connector

with the clip toward the outside.

Be sure the fuel hose connector is

securely snapped in place.

1 NOTICE 1 If the outboard end

fuel hose connector is forcibly in-

stalled in the reversed direction,

the fuel hose connector O-ring

seal can be damaged. A damaged

O-ring seal can cause a fuel leak.

OUTLET END

PRIMER BULB

3. Hold the primer bulb so that the

outlet end is higher than the inlet

end. The arrow on the primer

bulb points upward. Squeeze the

primer bulb several times until it

feels firm, indicating that fuel has

reached the carburetors. Check

for fuel leaks and repair any leaks

before starting the motor.

Do not squeeze the primer bulb

when the motor is running because

this could cause the carburetors to

overflow.

5. STARTING THE ENGINE (TILLER HANDLE TYPE)

ENGINE STOP SWITCH

SWITCH CLIP

piim%j

The nroneller must be

lowered into thi wker. Running the

outboard motor out of the water

will damage the water pump and

overheat the engine.

1. Engage the emergency stop switch

clip located at one end of the emer-

gency stop switch lanyard with the

engine stop switch. Attach the oth-

er end of the emergency stop switch

lanyard securely to the operator.

SPARE EMERGENCY

STOP SWITCH CLIP

A spare emergency stop switch clip is

provided near the engine stop switch.

B If the operator does

not attach the emergency stop

switch lanyard, and is thrown

from his seat or out of the boat,

the out-of-control boat can seri-

ously injure the operator, pas-

sengers, or bystanders. Always

properly attach the lanyard

before starting the motor.

GEAR SHIFF LEVER

2. Move the gearshift lever to the N

(neutral) position.

The engine will not start unless the

gearshift lever is in the N (neutral)

position.

5. STARTING THE ENGINE (TILLER HANDLE TYPE)

THROlTIiE GRIP

3. Align the engine start symbol

” Q, ” on the throttle grip with the

pointer ” w ” on the tiller handle.

’ /

CHOKE KNOB

4. When the engine is cold or ambient

temperature is low pull the choke

knob.

5. Press the start button and start the

engine. The starter motor con-

sumes a large amount of current.

Do not run it continuously for more

than 5 seconds at a time. If the

engine does not start within 5 sec-

onds wait at least 10 seconds before

using the starter motor again.

k!f@ Do not press the start but-

ton while the engine is running.

This can damage the starter motor

and flywheel.

5. STARTING THE ENGINE (TILLER HANDLE TYPE)

CHO;E K\NO;

THROTTLE GRIP

6. If it was necessary to use the choke knob to start the

engine, slowly return it to its initial position. Turn the

throttle grip in the SLOW direction to a position where

the engine does not stall.

-ATT---

WATER INTAKE

(each side)

7. After the engine starts, verify water is flowing through the

cooling system by monitoring the cooling system indicator.

The amount of water coming out of the cooling system

indicator will vary due to thermostat operation. Stop the

engine if water does not come out of the cooling system

indicator or if you see steam. Check the water intake

screens and the cooling system indicator discharge port

and if necessary remove any obstructions. If the problem

continues, contact your closest authorized Honda Marine

dealer.

-1 Ru

nning the outboard motor with an obstruc-

tion in the cooling system can damage the water pump

and overheat the engine.

5. STARTING THE ENGINE (TILLER HANDLE TYPE)

OIL PRESSURE

NORMAL: GREEN LIGHT ON

ABNORMAL: GREEN LIGHT

BLINKING OR OFF

8. With the engine running, check to

see if the green engine oil pressure

indicator light turns ON.

Stop the engine if the oil pressure

indicator light does not turn ON.

Check the engine oil level (see page

29). If the oil level is normal and

the oil pressure indicator light does

not turn ON, contact your closest

authorized Honda Marine dealer.

9. Warm up the engine as follows:

Above 41’F (YC) - run the engine

for 2 or 3 minutes.

Below 41’F (5°C) - run the engine

for at least 5 minutes at approximately

2,000 rpm.

Failure to completely warm up the

engine will result in poor engine

performance.

5. STARTING THE ENGINE (REMOTE CONTROL TYPE)

EMERGENCY

EkERGENCY STOP EMERGENCY STOP

SWITCH CLIP

SWITCH LANYARD

1 NoTlq ’ The propeller must be

lowered into the water. Running the

outboard motor out of the water will

damage the water’pump and over-

heat the engine.

1. Engage the emergency stop switch

clip located at one end of the emer-

gency stop switch lanyard with the

emergency engine stop switch.

Attach the other end of the emer-

gency stop switch lanyard securely

to the operator.

SPARE EMERGENCY

STOP SWITCH

CLIP

mmm

If the operator does

not attach the emergency stop

switch lanyard, and is thrown

from his seat or out of the boat,

the out-of-control boat can seri-

ously injure the operator, pas-

sengers, or bystanders. Always

properly attach the lanyard

before starting the motor.

The engine will not start unless the

emergency stop switch clip is engaged

with the emergency engine stop switch.

(nekl)

CONTRO

LEVER

A spare emergency stop switch clip is

provided on the remote control box.

2. Move the control lever to the N

(neutral) position.

The engine will not start unless the

control lever is in the N (neutral)

position.

5. STARTING THE ENGINE (REMOTE CONTROL TYPE)

3. When the engine is

cold or the

ambient temperature is low, lift the

choke/fast idle lever up fully. This

will provide a rich fuel mixture.

When the engine is warm, it

may be

necessary to

raise the choke/fast idle

lever slightly. Hold it in this position.

The choke/fast idle lever will not move

unless the control lever is in the N

(neutral) position.

4. Holding the choke/fast idle lever in

position, turn the ignition key to the

START position and release the key

when the engine starts. The starter

motor consumes a large amount of

current. Do not run it continuously

for more than 5 seconds at a time.

If the engine does not start within 5

seconds wait at least 10 seconds

before using the starter motor again.

[m Do not turn the ignition

key to the start position while the

engine is running. This can damage

the starter motor and flywheel.

5. After starting the engine, return the

lever slowly to the position where

the engine does not stall and hold

the lever in the position.

The control lever will not move unless

the choke/fast idle lever is returned

the lowest position.

5. STARTING THE ENGINE (REMOTE CONTROL TYPE)

COOLING SYSTEM

X’JDICATOR \

WATER INTAKE

(each side)

6. After the engine starts, verify water is flowing through the

cooling system by monitoring the cooling system indica-

tor. The amount of water coming out of the cooling sys-

tem indicator will vary due to thermostat operation. Stop

the engine if water does not come out of the cooling sys-

tem indicator or if you see steam. Check the water intake

screens and the cooling system indicator discharge port

and if necessary remove any obstructions. If the problem

continues, contact your closest authorized Honda Marine

dealer.

/=I Ru

nning the outboard motor with an obstruc-

tion in the cooling system can damage the water pump

and overheat the engine.

OiL PRESSURE

INDICATOR LIGHT

7. With the engine running, check to see if the green engine

oil pressure indicator light turns ON.

Stop the engine if the oil pressure indicator light does not

turn ON. Check the engine oil level (see page 29). If the

oil level is normal and the oil pressure indicator light does

not turn ON, contact your closest authorized Honda

Marine dealer.

8. Warm up the engine as follows:

Above 41’F (5°C) - run the engine for 2 or 3 minutes.

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

approximately 2,000 rpm.

Failure to completely warm up the engine will result in

poor engine performance.

5. STARTING THE ENGINE

Emergency Starting

(FRONT)

(REAR)

ENGINE COVER

LATCHES

If the electric starting system will

not

start the engine the engine can be

started by using the pull

emergency

rope from the tool kit.

1. Release the front and rear engine

cover latches then remove the

engine cover.

2. Remove the four 6 x 25 mm bolts

and the three washers then remove

the flywheel cover.

not lose the washers.

5. STARTING THE ENGINE

SHti LEVER

(TILLER HANDLE TYPE)

3. Depending on what type of out-

board motor you have, move the

shift lever or the control lever to the

N (neutral) position.

(neutral)

(REMOTE CONTROL TYPE)

ENGINE STOP SWITCH

SPARE EMERGENCC

- EMEkGENCY

STOP SWITCH

CLIP

4. If your outboard motor is a tiller

handle type, engage the emergency

stop switch clip, located at one end

of the emergency stop switch lan-

yard, with the’ engine stop switch.

A spare emergency stop switch clip is

provided near the engine stop switch.

5. STARTltNG THE ENGINE

OFF$

IGNITI

EMERGENCY

STOP SWITCH

CLIP

5. If your outboard motor is a remote

control type, turn the ignition key to

the ON position. Engage the emer-

gency stop switch clip, locatedat

one end of the emergency stop

switch lanyard, with the emergency

engine stop switch.

SPARE EMERGENCY

STOP SWITCH CLIP

A spare emergency stop switch clip is

provided on the remote control box.

/ CHOKEI(NOR

(TILLER HANDLE TYPE)

6. If the engine is cold or the ambient

temperature is low, pull the manual

choke knob located on the front of

the outboard motor.

5. STARTING THE ENGINE

(REMOTE CONTROL TYPE)

If the fuel system is working properly, it

should only be necessary to pull the

engine 1 or 2 times with the choke knob

out.

ENGINE START SYMBOL

POIN-TER

THROTTLE GRIP

(TILLER HANDLE TYPE)

7. On the tiller handle type align the

engine start symbol ” QI ” on the

throttle grip with the painter ” F ”

on the tiller handle. On the remote

control type.lift the choke/fast idle

lever. The choke/fast idle lever will

stay up in the fast idle position.

CHOKE/FAST

(REMOTE CONTROL TYPE)

5. STARTING THE ENGINE

OPE

1’

8. Set the emergency starter rope knot

in the notch in the flywheel and

wind the emergency starter rope

counterclockwise around the fly-

wheel.

9. pull the emergency starter rope

lightly until resistance is felt, then

pull briskly.

If the engine fails to start refer to

Troubleshooting page 96.

10X it was necessary to use the manu-

al choke knob to start the engine,

slowly return it to its initial

position.

11 .Slowly return the throttle grip to

the SLOW position or the

choke/fast idle lever to the lowest

position to where the engine does

not stall.

parts can cause-injury.

Use

extreme care when installing

the engine cover. Do not oper-

ate the outboard motor without

the engine cover.

12Leave the flywheel cover off and

install the engine cover. Lock the

engine cover latches. Attach the

emergency stop switch lanyard

securely to the operator and return

to the closest boat landing. Contact

your closest authorized Honda

Marine dealer and have the out-

board motor and the electrical sys-

tem checked.

5. STARTING THE ENGINE

“ikoubleshooting Starting Problems

SYMPTOM

Starter motor

doesn’t mm

over.

POSSIBLE CAUSE

1. Shift lever not in

neutral position.

2. Blown fuse.

REMEDY

1. Set shift lever in

neutral position.

2. Replace fuse.

(refer to page 90)

3. Weak battery. 3. Start by using starter

rope (refer to page 44)

1. Emergency stop switch

clip is not engaged.

1. Engage the emergency

stop switch clip

(refer to page 13 and 17)

Starter motor

turns over but

engine will not

Start.

2. Out of fuel

3. Vent knob not open.

2. Supply fuel.

(refer to page 30)

3. Open vent knob.

(refer to page 35)

4. Primer bulb has not

been squeezed.

4. Squeeze primer bulb to

supply fuel.

(refer to page 36)

5. Engine flooded. 5. Clean and dry spark plug.

(refer to page 83)

6. OIE’ERATION

Break-in Procedure

Break-in period 10 hours

Break-in operation allows the moving

parts to wear-in evenly and thus

ensures proper performance and

longer outboard motor life.

Break-in your new outboard motor as

follows:

First 15 minutes:

Run the outboard motor at trolling

speed. Use the minimum amount

of throttle opening necessary to

operate the boat at a safe trolling

speed.

Next 45 minutes:

Run the outboard motor up to a

maximum of 2,000 to 3,000 rpm or

10% to 30% throttle opening.

Next 60 minutes:

Run the outboard motor up to maxi-

mum of 4,000 to 5,000 rpm or 50%

to 80% throttle opening. Short

bursts of full throttle are acceptable

but do not operate the motor contin-

uously at full throttle.

Next 8 hours:

Avoid continuous full throttle oper-

ation (100% throttle opening). Do

not run the outboard motor at full

throttle for more than 5 minutes at a

time.

For boats that plane easily, bring the

boat up on plane

then reduce the throttle

opening lo the specified break-in

settings called out above.

6. OPERATION (TILLER HANDLE TYPE)

Gear Shifting

N (neutral)

FAST

POINTER

Gearshift lever has 3 positions:

FORWARD, NEUTRAL, and

REVERSE.

An indicator at the base of the

gearshift lever aligns with the letters F,

N, and R on the motor pan.

1. Align the pointer on the tiller han-

dle with the SLOW position on the

throttle grip to decrease engine

speed.

INiMCATOR

The throttle mechanism is designed to

limit the throttle grip travel when

operating in the

REVERSE

NEU-

TRAL

positions. The throttle grip can

only be turned to the

FAST

position

when operating in forward gear.

2. Put the tilt lever in the LOCK posi-

tion to prevent the outboard motor

from tilting up, when operating in

reverse (refer to page 22).

3. Move the gearshift lever to engage

the desired gear.

6. OPERATION (TILLER HANDLE TYPE)

Steering

RIGHT TURN

Move

the tiller

handle to the left.

LEFT TURN

Move the tiller

handle to the right.

The tiller handle is moved in the oppo-

site direction in which you want the

boat to turn.

Cruising

THRO&LE GRIP b

With the gearshift lever in the F (for-

ward) position, turn the throttle grip

toward the FAST mark to increase

speed. For optimum fuel economy,

limit throttle opening to 2/3.

RELEASE

To set the throttle at a steady speed,

turn the throttle friction knob clock-

wise. To release the throttle grip for

manual speed control, turn the friction

knob counterclockwise.

6. OPERATION (REMOTE CONTROL TYPE)

Gear Shifting

(neutral)

NEUTRAL

RELEASE

LEVER

I II I

PULL UP

OPENING

’ II 1

While pulling up the neutral release

lever, move the control lever 30

toward F (forward) or 30’ toward R

(reverse) to engage the desired gear.

Moving the control lever further from

30” will increase throttle opening and

boat speed.

(neutral)

i 30”

(reverse)

The control

lever will not move unless

the neutral release lever is pulled up and

choke/fast idle lever is in the lowest

position.

6. OPERATION (REMOTE CONTROL TYIE’E)

Cruising

POWER TRW/TILT

1. On the Power trim/tilt type, press

the DN portion of the power

trim/tilt switch and tilt the motor to

the lowest position.

(fo:ard)

(neutral)

2. Move the control lever from N

(neutral) 30’ toward F (forward) to

engage the F (forward) gear.

Moving the control lever further

from 30’ will increase the throttle

opening and boat speed.

3. For optimum fuel economy, limit

throttle opening to 2/3.

6. OPERATION (GAS ASSISTED TILT TYPE)

Tilt Lever

GEARSHIFT

Tilt the motor up to prevent the pro-

peller and gear case from hitting the

bottom when beaching or stopping in

shallow water.

1. Move the gearshift lever to the

N ( neutral) position and stop the

engine.

\ \u\\ PUSH

SWITCH

ENGINE COVER GRIP

‘TILT LEVER

2. To tilt the motor up, move the tilt

lever to the FREE position, then

pull the engine cover grip and raise

the motor.

6. OPERATION (GAS ASSISTED TIILT TYPE)

3. With the outboard motor tilted up to

the desired position, move the tilt

lever to the LOCK position to lock

the motor.

To lower the

motor

back down,

move the tilt lever to the FREE

position, while holding the engine

cover grip, then lower the motor

gently. Move the tilt lever

LOCK position.

The tilt lever must be in the LOCK

position before operating the motor or

the motor could tilt up when operating

in reverse.

6. OPERATION (GAS ASSISTED SYSTEM)

TILT LOCK

Use the tilt lock lever to hold the

motor in the highest tilt position when

the boat is moored for a long time.

1. Move the tilt lever to the FREE

position (refer to page 56), then pull

the engine cover grip and tilt the

motor all the way up.

2. Move the tilt lock lever to theLOCK

position and lower the outboard

motor slowly.

3. Move the tilt lever to the LOCK

position.

4. To lower the motor, move the tilt

lever to the FREE position. Lift up

on the engine cover grip and swing

the tilt lock lever to the free posi-

tion.

5. Lower the engine gently. Move the

lever to the LOCK position.

6. OPERATION (POWER TRIFdTILT TYPE)

XRTA type outboard (refer to page 20)

The power trim/tilt system can adjust

the motor angle while cruising, or the

motor tilt angle while mooring. Motor

trim angle adjustment is necessary to

compensate for boat load or weight

distribution, water conditions, pro-

peller or engine condition. The motor

trim angle can be adjusted while

accelerating or cruising to obtain the

maximum boat speed, optimum boat

stability, and fuel economy. Under

normal conditions, the boat will

achieve optimum boat performance

when the motor is running at maxi-

mum t-pm and the ventilation plate is level

with the water.

Press either the UP or DN portion of

the power trim/Mt switch and trim the

motor to the best position for the

cruising conditions.

The power trim/tilt system operates

when the switch is pressed,and it stops

when the switch is released.

POWER TRIMfllLT SWITCH

Press UP

tu raise p

bow.

Press DN to

lower

bOW.

CONTROL LEVER

INOTICE] Excessive trim/tilt angle

during operation can cause the pro-

peller to raise out of the water and

cause propeller ventilation and

engine over-revving. Excessive

trim/tilt angle rzn also damage the

water pump and overheat the

engine.

To trim motor up slightly, press the

UP portion momentarily.

To trim motor down slightly, press the

DN portion momentarily.

’ 20’

0’ TRIM ANGLE

Decrease the trim angle on high speed

turns to reduce the possibility of prope

ler ventilation.

!I-

Improper motor trim angle can result in

an unstable steering condition. The

power trim/tilt warning system will be

activated and an intermittent buzzer

sounds when the motor is trimmed

excessively (refer to page 65).

6. OPERATION (POWER TRIM/TILT TYPE)

MOTOR TRIMMED MOTOR TRIMMED

TOO LOW

TOO HIGH

R’OIJGH

MOTOR TRIMMED

WAVES

CORRECTLY

When cruising:

(A) Into a high wind, trim the motor

down slightly to level the bow and

improve boat stability.

(B) With a tail wind, trim the motor

up slightly to raise the bow and

improve boat stability.

trim the motor too low or too

high to avoid an unstable steer-

ing condition.

‘lkim Meter

The trim meter indicates the trim angle of the motor.

Refer to the trim meter, and

press the UP or DN portion of the power trim/tilt switch to adjust. the motor trim

angle to achieve boat performance and stability.

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR

2. MOTOR TRIMMED TOO HIGH

BOW TOO LOW DUE TO

1. LOAD IN THR FRONT’

2. MOTOR TRIMMED TOO LOW

With the motor trimmed low the trim

meter will read as shown. To raise the

bow increase the motor trim angle by

pressing the UP portion of the power

trim/tilt switch.

With the motor trimmed high the trim

meter will read as shown. To lower

the bow decrease the motor trim angle

by pressing the DN portion of the

power trim/tilt switch.

6.~PERATIOlV (POWER TRIM/TILT TYPE)

Power Tilt Switch (Motor Pan)

POWkR TILT SWITCH

The power tilt switch located on the

motor pan is a convenience switch for

tilting the motor for trailering, or per-

forming outboard motor maintenance.

This power tilt switch should only be

operated when the boat is stopped and

the motor is off.

Manual Relief Valve

.IEF

MANUAL

(To release)

Do not turn this screw. If this screw is

turned hydraulic oil will bleed out of

the power trim/tilt system. Should this

happen it will be necessary to contact

your closest authorized Honda Marine

dealer and have the system refilled.

If the power trim/tilt switch will not

tilt the outboard motor, the motor can

be manually tilted up or down by

operating the manual relief valve. To

tilt the outboard motor manually, turn

the manual relief valve under the left

stem bracket no more than 1 or 2 turns

counterclockwise using a screw driver.

After tilting the motor, turn the manual

relief valve clockwise securely. The

manual relief valve must be tightened

securely before operating the motor or

the motor could tilt up when operating

in reverse.

6. OPERATION (POWER TRIM/TILT TYPE)

LEVER

Tilt Lock Lever

Use the tilt lock lever when the boat is

moored.

1. Tilt the motor up as far as it will go

using the power trim/tilt switch.

2. Move the tilt lock lever to the

LOCK position and lower the out-

board motor until the lock lever

contacts the stem bracket (refer to

page 23).

It may be necessary to lift the engine

cover grip slightly to swing the tilt lock

lever into the LOCK position.

3. To lower the motor, tilt the motor

up slightly, move the tilt lock lever

to the FREE position, and lower the

motor to the desired position.

6. OPERATIBFJ

‘Ikim Tab Adjustment

TIGHTENING B

The trim tab is provided to adjust for

“torque steer” which is a reaction of

the propeller rotation or propeller

torque. If during a high speed turn an

unequal amount of effort is required to

turn the boat right or left, adjust the

trim tab so that an equal amount of

effort is required.

Distribute the load evenly in the boat

and run the boat in a straight course at

full throttle. Slightly turn the steering

wheel or tiller handle for both right

and’ left turns to determine the amount

of effon required.

If less effort is required to make left

turns:

Loosen the trim tab tightening bolt

and turn the rear end of the trim tab

toward the left. Tighten the bolt

securely.

If less effort is .required to make right

turns:

Loosen the trim tab tightening bolt

and turn the rear end of the trim tab

toward the right. Tighten the bolt

securely.

Make small adjustments at a time and

retest. Incorrect trim tab adjustment

can cause adverse steering.

The trim tab also functions as a sacrifi-

cial anode.

-1 Painting or coating

the

anode will lead to rust and corrosion

damage to the outboard motor

6. OPERATION (MOTOR PROTECTION SYSTEM)

Engine Oil Pressure and Overheat Warning System

If the engine oil pressure drops andfor

the engine overheats, either or both

warning systems could be activated.

When activated the engine speed will

decrease gradually and the green oil

pressure indicator light will turn OFF

and’the red overheat indicator light

will turn ON. A continuous buzzer

will sound on the remote control type.

The engine speed can not be increased

with a larger throttle opening until the

malfunction is corrected. When the

malfunction is corrected the engine

speed will increase gradually.

INDICATOR LIGHTS

6. OPERATION (MOTOR PROTECTION SYSTEM)

When the oil pressure warning sys-

tems is activated:

1. Stop the engine immediately and

check the engine oil level (refer to

pqze 29).

2.If the oil is up to the recommended

level, restart the engine. If the oil

pressure warning system stops after

30 seconds, the system is normal.

If the throttle

was closed suddenly after

cruising at full throttle, the engine speed

may drop below the specified idle speed.

This’could cause the oil pressure

warning system to activate momentarily.

3. If the oil pressure warning system

stays activated after 30 seconds,

return to the closest boat landing

and contact your closest authorized

Honda Marine dealer.

COOLING SYSTEM INDICATOR

When the overheat warning system is

activated:

1. Return the gearshift lever or control

lever to the N (neutral) position

immediately. Check to see if water

is flowing out of the cooling system

indicator.

2. If water is flowing out of the cool-

ing system indicator, continue

idling for 30 seconds. If the over-

heat warning system stops after 30

seconds the system is normal.

If the motor is turned off after running at

full throttle, the engine temperature may

rise above

normal.

If the

motor is

restarted, shortly after being

turned off,

the overheat warning system could be

activated momentarily.

3. If the overheat warning system

stays activated, stop the engine. tilt

up the motor and check the water

intakes for obstructiotls. If there are

no obstructions at the -water intakes,

return to the closest boat landing

and contact your closest authorized

Honda Marine dealer.

6. OPERATION (MOTOR PROTECTION SYSTEM)

Over-Rev Limiter

This outboard motor is equipped with

an engine over-rev limiter which acti-

vates when the engine speed increases

excessively. The over-rev limiter can

be activated while cruising, tilting up

the motor, or when ventilation occurs

during a sharp turn.

When the over-rev limiter is activated:

1 .Reduce the throttle opening immedi-

ately and check the trim angle.

23 the trim angle is correct but the

over-rev limiter stays activated,

stop-the engine and check the con-

dition of the outboard motor and

check the propeller for damage.

Correct or service as necessary,.

Power lkim Warning System

If the motor trim angle is more than

20” and the control lever is moved

more than 40’ forward/rearward from

the N (neutral) position, an intermit-

tent buzzer will sound and beep at one

second intervals.

6. OPERATION (MOTOR PROTECTION SYSTEM)

When the power trim warning system

is activated:

1. Immediately decrease the trim

angle by pressing the DN portion of

the power trim/tilt switch.

2. Immediately reduce the tiottle

opening to SLOW and Operate the

engine at low speed.

Anodes

The anodes are a skxificial material The anodes are a skxificial material

which helps to protect the outboard which helps to protect the outboard

motor from corrosion. motor from corrosion.

1 NOTICE) Painting or coating the

anodes will lead to rust and corrosion

damage to the outboard motor.

There are also 2 small sacrificial anodes

in the water passages of the engine

block.

6. OPERATION

Shallow Water Operation

-[Excessive trim/tilt angle

during operation can cause the pro-

peller to raise out of the water and

cause propeller ventilation and

engine over-revving. Excessive

trim/tilt angle can also damage the

water pump and overheat the

engine.

When operating in shallow water, tilt

the motor up to prevent the propeller

and gear case from hitting the bottom

(refer to pages 55 and 58). With the

motor tilted up, operate the motor at

low speed.

Monitor the cooling system indicator

for water discharge. Be sure that the

motor is not tilted so high that the

water intakes are out of the water.

If an excessive amount of throttle is

used when operating in forward gear,

the motor will return to the transom

angle adjusting rod.

(Gas assisted tilt type).

If the motor trim angle is more than

20” and the control lever is moved

more than 40’ forward/rearward from

the N (neutral) position, the power

trim warning system will be activated

(refer to page 65).

(Power trim/tilt type).

6. OPERATION

High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture

will be too rich. Performance will decrease, and fuel con-

sumption will increase. A very rich mixture will also foul

the spark plugs and cause hard starting.

High altitude performance can be improved by specific

modifications to the carburetors. If you always operate

your outboard at altitudes above 6,000 feet (1,800 meters)

have an authorized Honda Marine dealer perform this car-

buretor modification.

Even with carburetor modification, engine horsepower

will decrease about 3.5% for each I.000 foot (300 meter)

increase in altitude. The effect of altitude on horsepower

will be greater than this if no carburetor modification is

made.

NOTICE When the carburetors have been modified

for high altitude operation, the air-fuel mixture will be

too lean for low altitude use. Operation at altitudes be-

low 6,000 feet (1,800 meters) with modified carbure-

tors may cause the engine to overheat and result in

serious engine damage. For use at low altitudes, have

an authorized Honda Marine dealer return the carbu-

retors to original factory specifications.

7. STOPPING THE ENGINE (TILLER HANDLE TYPE)

Emergency Engine Stop

ENGINE STOP SWITCH

EMERGENCY STOP

SWITCH LANYARD

L SWITCH CLIP

Disengage the emergency stop switch

clip from the engine stop switch by

pulling the emergency stop switch lan-

yard.

It is a good idea to stop the engine with

the emergency stop switch lanyard from

time to time to be sure that the switch is

operating properly.

Normal Engine Stop

THROTTLE GRIP

1. Turn the throttle grip to SLOW

position and move the gearshift lev-

er to N(neutral).

GEARSHIFT LEVER

,’

7. STOPPING THE ENGINE (TILLEIR HANDLE TYPE)

PUSH

2. Push the engine stop switch until

the engine stops.

7. STOPPING THE ENGINE (REMOTE CONTROL TYPE)

Emergency Engine Stop

EMERGENCY

EMERGENCY STOP

\\\\ \\

SWITCH LANYARD

EMERGENCY STOP SWITCH CLIP

Disengage the emergency stop switch

clip from the emergency engine stop

switch by pulling the emergency stop

switch lanyard.

It is a good idea to stop the engine with

the emergency stop switch lanyard from

time

to time to be sure that the switch is

operating properly.

Normal Engine Stop

N (neutral)

1. Move the control lever to the N

(neutral) position and turn the igni-

tion key to the OFF position.

IGNITION KEY

When the boat is not in use, remove

and store the ignition key.

8. TRANSPORTING

Trailering

STEERING FRICTION

When trailering or transporting the

boat with the motor attached, it is

recommended that the motor remain

in the normal run position. Tighten

the steering friction adjuster se-

curely lo stop the motor’s side to

side tiovement.

If there is insufficient road clearance

with the motor in the normal run po-

sition, then trailer the motor in the

tilted position using a motor support

bar (refer to your motor support bar

manufacturer’s instructions) or re-

move the motor from the boat.

Close the fuel cap vent knob (refer

to page 27).

Disconnect the fuel coupling from

the outboard motor (refer to page

35).

Horizontal Transport

CASE PROTECTORS

Before removing the motor from the

boat, drain the carburetors. Follow

the carburetor drain procedure on

page 94.

Always rest the motor on the case

protectors and be sure to protect it

from impact and damage.

9. CLEANING AND FLUSHING

WASH PLUG (flush plug)

Thoroughly clean and flush the out-

board motor with fresh water after

operating in dirty or salty water.

Flush Kit (optional part)

1. Wash the outside of the outboard

motor with clean, fresh water.

2. Remove the wash plug and sealing

washer from the WASH plug hole

in the gear case. Be sure not to

remove the oil level plug from the

OIL LEVEL plug hole in the

gear case.

FLUSH KIT COUPLER

B Keep children and

pets away from the area, and

stay clear of all moving parts

during this procedure.

3. Remove the sealing washer from

the wash plug and install the sealing

washer on the flush kit coupler.

4. Install the flush kit coupler into the

WASH plug hole and connect a

fresh water hose to the flush kit

coupler.

5. Move the gearshift lever or control

lever to the N (neutral) position.

Blush the outboard motor in the

neutral position only.

6. Turn on the fresh water supply to

the flush kit coupler.

I- Running the outboard

motor without sufficient cooling

water will damage the water pump

and overheat the engine.

9. CLEANING AND FLUSHING

CdoLINb SYSTEM

INDICATOR

7. Start the engine. Monitor the cool-

ing system indicator. Stop the

engine if water does not come out

of the cooling system indicator and

check the fresh water supply. If the

fresh water supply is insufficient it

may be necessary to temporarily

cover the three water intakes with

duct tape.

8. Allow the engine to run at idle for

at least 5 minutes to clean the inside

of the motor.

9. Stop the motor and remove the

flush kit coupler.

lO.Remove the sealing washer from

the flush kit coupler and install the

sealing washer on the wash plug.

If tape was used to cover the three water

intakes in step 7, remove the tape now.

11 .Install the wash plug into the gear

case securely.

10. MAINTENANCE

Periodic maintenance and adjustment

are important to keep the motor in the

best operating condition. Service and

inspect according to the MAINTENA-

NCE SCHEDULE.

Stop the engine before performing any

maintenance.

If it is necessary to run the engine

make sure the area is well ventilated.

Never run the engine in an enclosed or

confined area.

Exhaust contains

poisonous carbon monoxide

gas; exposure can cause loss of

consciousness and may lead to

death.

m Running the outboard

motor without sufficient cooling

water will damage the water pump

and overheat the engine.

To maintain the cooling system effi-

ciency, flush the outboard motor with

fresh water after operating in salt

water or dirty water. Make sure there

is at least 2 inches of water above the

ventilation plate. Or follow the flushing

procedure (refer to pages 73 and 74).

10. MAINTENANCE

Tool Kit and Spare Parts

The following tools and spare parts

are supplied with the outboard motor

for maintenance, adjustment, and

emergency repairs.

TOOL KIT

10 x 12

WRENCH

WRENCZI

FLAT SCREWDRIVER

-==n

PHILLIPS SCREWDRIVER

OIL CHECK SCREWDRIVER

PLIERS

SCREWDRIVER HANDLE

TOOL BAG

18 x 19

SOCKET

WRENCH

10. MAINTENANCE

MAINTENANCE SCHEDULE

Use only genuine HONDA parts or their equivalent for maintenance or repair.

Replacement parts which are not of equivalent quality may damage the motor.

REGULAR SERVICE PERIOD (3)

Performed at every indicated FIRST

EVERY

month or operating hour EACH USE 20 HRS

100 HRS OR

200 HRS

400 HRS OR

intervals, whichever comes first. OR MONTH

6 MONTHS

OR YEARLY

2 YEARS

Engine oil Check level

Change

Gear case oil Check level and Check

for water contamination

Engine oil filter

Change

0 0

Change

O(2)

10. MAINTENANCE

REGULAR SERVICE PERIOD (3)

Perform at every indicated month

or operating

hour,

intervals,

whichever comes first.

Fuel tank and filter

ClCUl

filter

(Replace if necessary)

FIRST

EVERY

EACH USE

20 HRS

100 HRS OR

200 HRS

400 HRS OR

OR MONTH

6MONTHS

OR YEARLY

2 YEARS

Fuel filter

Check 0

Chanee I

l%ermostat

Check

I I I

O(2)

Fuel line

Check

(Replace if necessary)

Battee fluid

Check-refilling (if necessary)

Cable connection Check-tightness

Bolts and Nuts

Check-tighmess

O(2)

0 0

O(2) O(2)

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

(2) These items should be serviced by an authorized Honda Marine dealer, unless

the owner has the proper tools and is mechanically proficient. See the Honda

Shop Manual.

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

maintenance intervals.

10. MAINTENANCE

Engine Oil

Engine oil is a major factor affecting

engine performance and service life.

Oil check interval:

Each use.

Oil change interval:

After the first 20 hours, then every

100 hours. (Refer to the mainte-

nance schedule page 77).

OIL CAPACITY:

2.1 US qt (2.0 lit)...When oil filter is

not replaced

2.5 US qt (2.4 lit)....When oil filter is

replaced

Recommended oil:

BF35A...SAElOW-30 engine oil or

equivalent, API Service classification

SG, SH.

BF40Al50A...SAE5W-30 engine oil,

API Service classification Fuel Efficient

SG. SH.

Engine Oil Replacement

Drain the oil while the engine is still

warm to assure rapid and complete

draining.

1. Position the outboard motor verti-

cally, and remove the engine

cover.

Remove the oil filler cap.

10. MAINTENANCE

DHAINPLUG

2. Loosen the drain plug cover screw

using a flat blade screwdriver and

remove the drain plug cover.

3. Place the drain plug cover as shown

to use it as an oil drain guide. Place a

suitable contaiuer under the guide.

4. Remove the engine oil drain bolt

and washer using a 12 mm wrench

and drain the engine oil.

5. Install a new sealing washer on the

drain bolt and tighten the bolt

securely.

6. Reinstall the drain plug cover.

10. MAINTENANCE

7. Refill to the upper level mark on the

oil level dipstick with the recom-

mended oil.

NOTE: To ,avoid incorrect gauging

of the engine oil level, inspect the oil

level when the engine has cooled. The

outboard motor needs to be in the

vertical position.

8. Reinstall the oil filler cap.

Always wash your hands after handling

used oil.

Also, please dispose of used motor oil in

a manner that is compatible with the

environment. We suggest you take it in a

sealed container to your local service

station reclamation center. Do not throw

it in the trash, pour it on the ground,

down a drain, or into the water.

Gear Oil

Oil check interval:

Every 100 hours.

Oil change interval:

After the first 20 hours, then every

100 hours. (Refer to the mainte-

nance schedule page 77).

OIL CAPACITY:

0.53 US qt. (0.5 lit)

Recommended oil:

Outboard motor SAE 90 hypoid

gear oil API Service Classification

(GL-4 or GL-5).

10. ‘MAINTENANCE

LEVEL PLUG

Gear Oil Level/Check

1. Position the outboard motor verti-

cally.

2. Remove the level plug and see if oil

flows out. If no oil flows out, fill

through the drain plug hole until the

oil starts to flow out through the level

plug hole. If there is water in the oil,

the water will flow out first when the

drain plug is removed, or the oil will

be milky colored. If the oil appears

abnormal contact your closest

authorized Honda Marine dealer.

GEAR OIL BOITLE

A gear oil bottle is recommended to

fill the gear case.

The end of the drain plug is a mag-

net. Remove all metal particles from

the end of the drain plug before

reinstalling. Do not reinstall the drain

plug in the level plug hole.

3. Use new sealing washers and rein-

stall the level plug and drain plug

securely.

Gear Oil Change

1. Position the outboard motor verti-

cally.

2. Remove the level plug and drain

plug to drain the oil. Inject oil

through the drain plug hole until it

starts flowing out through the level

plug hole. Use new sealing washers

and reinstall the level plug first and

then the drain plug securely.

OIL CAPACITY:

0.53 US qt. (0.5 lit)

10. MAINTENANCE

Spark Plugs

To ensure proper engine operation, the

spark plugs must be properly gapped

and free of deposits.

Check-replace interval:

After the first 20 hours, then every

200 hours. (Refer to the mainte-

nance schedule page 77).

Recommended spark plug:

DR7EA (NGK),

X22ESR-U (NIPPON DENSO)

Use only the recommended spark

plugs or equivalent.

-1 Spark plugs which have

an improper heat range may cause

engine damage.

1. Allow the engine to cool. The spark

plugs will be hot if the engine has

been running.

2. Remove the engine cover.

PLUG CAPS

- v

3. Disconnect the spark plug caps

from the spark plugs.

4. Use the wrench and screwdriver

supplied in the tool kit to remove

the spark plugs.

5. Check the spark plugs. Replace the

spark plugs if there is apparent

wear, or if the insulators are

cracked or chipped. Clean the spark

*plugs with a wire brush if they are

to be reused.

: 0.024-0.028 in

(0.6-0.7

mm)

6. Measure the plug gaps with a spark

plug gap gauge.

The gaps should be 0.024-0.028 in

(0.6-0.7 mm). Correct as necessary

by carefully bending the side elec-

trode.

10. MAINTENANCE

7. Thread the plugs in by hand to pre-

vent cross threading.

8. After the spark plugs are seated,

tighten with a spark plug wrench to

compress the washers.

If installing new spark plugs, tighten i/2

turn after the spark plugs seat to com-

press the washers. If reinstalling used

spark plugs, tighten l/8-

l/4

turn after

the spark plugs seat to compress the

washers.

m The spark plugs must be

securely tightened. Aloose spark

plug can become very hot and may

cause engine damage.

Overtightening the spark plugs can

damage the threads.

Battery (not included)

Minimum requirements

12V-70AH marine cranking battery.

Maintenance interval

Refer

to the maintenance schedule

page 78 and your battery manufac-

turer’s instructions for servicing or

recharging information.

Check the battery cables to be sure

they are securely connected to the bat-

tery terminals. lighten if necessary.

If the battery terminals are corroded or

if recharging is necessary, remove the

battery from the boat to clean or

recharge.

10. MAINTENANCE

tains corrosive sulfuric acid.

Contact with eyes or skin caus-

es burns.

Wear protective clothing and

use eye protection when

working near the

battery.

POISON - KEEP OUT OF REACH

OF CHILDREN

NEGATIVE (-)

CARRYING

~013 BATTERY

TERMINAL

POSITIVE

(+) BATTERY CABLE (red)

EMERGENCY PROCEDURES:

Eyes

Flush with water from a cup or oth-

er container for at least 15 minutes.

Call a physician immediately.

Skin

Remove contaminated clothing.

Flush skin with large quantities of

water. Call a physician.

If swallowed

Drink water or milk and call your

local poison control center or physi-

cian immediately.

Battery cleaning

B Batteries pioduce

explosive hydrogen gas. A spark

or flame can explode the battery

causing serious Injury or blind-

ness. Provide adequate ventila-

tion.

Keep sparks and flames away.

Follow the procedure below

carefully.

Removal:

1. Disconnect the negative ( - ) battery

cable first, then disconnect the posi-

tive (+) battery cable.

2. Remove the battery from the boat.

Clean the battery terminals with a

wire brush or sand paper. Clean the

battery with a solution of baking soda

and warm water, taking care not to

get the solution of water in the

battery cells. Dry the battery thor-

oughly.

3. Clean the battery cable ends with a

wire brush or sand paper.

10. MAINTENANCE

Insthation:

To protect the battery from mechani-

cal damage and to prevent the bat-

tery from falling or tipping over, the

battery must be:

Installed in the correct size corro-

sion-resistant battery box.

Properly secured in the boat.

Secured in a location free from di-

rect sunlight and water spray.

Secured away from the fuel tank

to avoid potential sparks near the

fuel tank.

1. Return the battery to the boat and

install it in the battery box.

2. Connect the positive (+) battery

cable first, then connect the nega-

tive (-) battery cable. Tighten the

cable nuts securely.

3. Coat the battery terminals and ca-

ble ends with marine anticor-

rosion grease.

4, Put the cover on the battery box and

secure the battery box to the boat.

Lubrication

Lubrication interval: After the first 20 hours, then every 100 hours.

(Refer to the maintenance schedule page 77.)

Apply marine anticorrosion grease to the following parts:

r THROTI’LE REEL

10. MAINTENANCE

Engine Fuel Filter

FUEL FILTER

The engine fuel filter is located under

the engine cover between the fuel cou-

pling and the fuel pump. Water or

sediment accumulated in the fuel filter

can cause loss of power or hard start-

ing.

Check interval:

Every

100 hours

(Refer

to the main-

tenance schedule page 78.)

Change interval:

Every 400 hours (Refer to the main-

tenance schedule page 78.)

w Gasoline is

extremely flammable, and gaso-

line vapor can explode, causing

serious injury

death. Do not

smoke or allow flames or sparks

in your working area. KEEP

OUT OF REACH OF CHILDREN.

Always work in a well-ventilated area.

Make sure that any fuel drained from

the outboard motor is stored in an

approved gasoline container. Be care-

ful not to spill any fuel when replacing

the filter. Spilled fuel or fuel vapor

may ignite. If any fuel spilled, make

sure the area is dry before starting the

engine.

CONNECTOR

FUEL HOSE

Check

1. Disconnect the fuel hose connector

from the outboard motor.

2. Pull the choke knob fully

and

remove the engine cover.

10. MAINTENANCE

Pull the spring retainer toward you,

and raise the fuel filter.

4. Check the fuel filter for water accu-

mulation or sediment. If no water

or sediment are found, reinstall the

fuel filter properly.

FUEL HOSES

Change

1. Remove the fuel filter.

Before removing the fuel filter. to

prevent fuel leakage, place fuel hose

clamps on the fuel hoses at each side of

the fuel filter.

ARROW (Fuel Flow Direction)

2. Install the new fuel filter so the

arrow on the fuel filter points

toward the fuel pump.

Fuel flow will be reduced if the fuel

filter is installed backward.

3. Connect the fuel hoses to the fuel

filter securely with the hose clips.

Remove the fuel hose clamps used

to close the fuel hoses.

10. MAINTENANCE

4. Securely connect the fuel hose con-

nector to the outboard motor page

35.

5. Prime the engine using the primer

bilb page 36. 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.

Fuel Tank and Filter

Cleaning interval:

Every 200 hours (Refer to the

maintenance schedule page 78).

Inspect the condition of the fuel cap

gasket, fuel hose, and the O-ring seals

in the fuel hose connectors. Replace

the fuel cap gasket, hose, or fuel con-

nectors if they are cracked, damaged

or leak fuel. Be sure the fuel hose is

not kinked.

Fuel ‘Ihnk Cleaning

1. Disconnect the fuel hose from the

fuel tank.

extremely flammable, and gaso-

line vapor can explode, causing

serious injury or death. Do not

smoke or allow flames or sparks

in your working area. KEEP ’

OUT OF REACH OF CHILDREN.

2. Empty the gasoline from the fuel

tank into an approved gasoline con-

tainer. Pour in a small quantity of

fresh gasoline,

and

clean the tank

thoroughly. Drain and dispose of

the gasoline properly.

lO.:MAINTENANCE

FUEL TANK HOSE

CONNECTOR

FUEL TANK

FILTER

Fuel Tank Filter

Cleaning/Replacement

Turn the fuel tank hose connector

counterclockwise to remove the

fuel tank filter.

2. Clean the fuel tank filter with non-

flammable cleaner or

solvent.

Replace the fuel tank filter if neces-

sary*

3. After cleaning or replacement, rein-

st$l the fuel tank filter and fuel

tank hose connector securely.

Fuse Replacement

BLOWN FUSE

If the fuse is blown, running the engine

will not charge the battery and the

electric starter will not work.

FUSE

RATING:

15A

Never use a fuse. with a different rat-

ing from that specified.

If the fuse is blown, check the cause,

then replace the fuse with a spare fuse

of the same rated capacity. Unless the

cause is found, the fuse may blow

again.

FUSE COVER

Replacement

1. Stop the engine.

2. Remove the engine cover.

3. Pull the blown fuse out of the clip.

4. Push a new 15A fuse into the clip.

A spare 15A fuse is located in the fuse

holder. If the spare fuse is not available,

the motor will need to be started with the

pull starter rope (refer to the emergency

start procedure page 44).

10. MAINTENANCE

Propeller

ECIAL SPLINE WASHER

PROPELLER

THRUST WASHER

MARINE GREASE

45i!i

If the propeller is damaged, replace it

as follows:

Removal:

Hand tighten the castle nut until the 4

Remove the cotter pin then remove the

16 mm castle nut, 17 mm plain

mm cotter pin can be installed. If

washer, 10 mm special spline washer,

necessary, tighten the castle nut just

propeller and thrust washer.

enough to align the hole with the groove

in the nut.

COTTER PIN (stainless)

Installation:

Install

the thrust washer with the

grooved side toward the gear case, then

install the new propeller in the reverse

sequence of removal.

Use a new genuine Honda cotter pin

and bend the cotter pin ends as shown.

10. MAINTENANCE

Submerged Motor

A submerged motor must be serv-

iced immediately after it is recov-

ered’from the water inorder to

mimumize corrosion.

Immediately take the outboard mo-

tor to the closest authorized Honda

Marine dealer or if you are far from

a dehlership, proceed as follows:

I. Remove the engine cover, and

rinse the motor with fresh water

to remove salt water, sand, mud,

etc.

2. Drain the carburetors (Refer to

Storage page 94).

3. Disengage the emergency stop

switch clip from the emergency

stop switch.

4. Remove the spark plugs.

EMERGENCY STARTEli

ROPE

Remove the flywheel cover fol-

lowing

the emergency starting

procedure (refer to page 44) and

remove the water from the cylin-

ders by pulling the emergency

starter rope several times. If the

motor was running when it sub-

merged, there may be mechanical

damage, such as bent connecting

rods. If the engine binds when ro-

tated with the emergency starter

rope, do not proceed or attempt to

run the motor until it has been

repaired.

6. Change the engine oil (refer to

page 79).

7. Put a teaspoon of engine oil into

each spark plug hole to lubricate

the inside of the cylinders. Then

rotate the engine several times, us-

ing the emergency starter rope.

Reinstall the spark plugs.

-1 Running the outboard

motor without suffkient cooling

water will damage the water

pump and overheat the engine.

10. MAINTENANCE

8. Engage the emergency stop

switch clip with the emergency

stop switch and attempt to start

the engine (be sure the water

level is at least 2 inches above the

anti-ventilation plate).

l If the engine fails to start, re-

move the spark plugs, clean

and dry the electrodes, then re-

install the spark plugs and at-

tempt to start the engine again.

l If the engine starts, and no me-

chanical damage is evident,

continue run the engine for a l/2

hour or longer.

l If there was water in the en-

gine crankcase, or the used en-

gine oil showed signs of water

contamination, then a second

engine oil change should be

performed after running the en-

gine for a l/2 hour.

9. Take the outboard motor to your

closest authorized Honda Marine

dealer for inspection and service

as soon as possible.

lit STORAGE

For longer service life of the outboard

motor,‘have your outboard motor ser-

viced by an authorized Honda Marine

dealer before storage.

If you are unable to take the motor to

your dealer, proceed as follows:

Draining the Carburetors

B Gasoline is

extremely flammable, and gaso-

line vapor can explode, causing

serious injury or death. Do not

smoke or allow flames or sparks

in your working area, KEEP OUT

OF REACH OF CHILDREN.

Be careful not to spill gasoline. Spilled

gasoline or gasoline vapor may ignite.

If any gasoline is spilled, make sure

the area is dry before storing or trans-

porting the motor. Do not smoke or

allow flames or sparks where gasoline

is drained or stored.

DRAII’i SCREW

1. Disconnect the fuel hose connector.

2. Pull the #3 carburetor drain hose

outside of the motor pan.

3. Loosen the drain screw of the #3

carburetor and drain the carburetor.

Catch the draining gasoline in an

approved gasoline container.

4. Dram the #I and #2 carburetors in

the same manner using the #3 car-

buretor dram hose.

DRA

tlos

KZCARBURETOR

#l CARBURETOR

#3CARBURETOR

DRAIN SCREW

5. After thoroughly draining the car-

buretors, tighten the drain screws

securely.

6. Reinstall the drain hose back on the

#3 carburetor.

11. STORAGE

Fuel Tank

VENT KNOB

FUEL CAP

1. Close the fuel cap vent knob.

2. Disconnect the fuel coupling

from the outboard motor (refer to

page 35).

Outboard Motor Position

Transport and store the motor either

vertically or horizontally, as shown

above. Store the outboard motor in a

well-ventilated area free from direct

sunlight and humidity.

Vertical transport or storage:

Attach the stem bracket to stand.

CASE PROTECTORS

Horizontal transport or storage:

Rest the motor on the case protectors.

1 NOTICE 1 Improper transport or

storege can damage the motor or

cause oil leakage.

12.8 TROUBLESHOOTING

(1) Engine does not start.

Fuel

Fuel is not fed -

to carburetor.

There is no gasoline

in fuel tank.

Vent knob is not open or

vent clogged.

Fuel filter is clogged.

Fuel line is kinked.

Fuel line is connected

improperly.

Fuel pump is faulty.

primer bulb is faulty.

Check valve in connector

is faulty

clogged.

Electrical

Sparks across

Insufficient - Spark plug gap is small.

sparblw gap

sparks

Wcalc starter motor

rotation.

Normal -

Recheck the fuel system.

sparks

No sparks -

across spark

plug gap

Spark plug -,-,- Contamination

is faulty.

L- Incorrect gap

Broken spark plug

lTll

Fulser coil is faulty.

Current leaks from

high tension cord.

- C.D.I. unit is faulty.

I I ‘-

Exciter coil is faulty.

Ignition coil is faulty.

Wire harness is faulty.

Current leaks from engine stop

switch cord.

Stop switch does not return

satisfactorily.

- Spark plug is improperly installed.

- Emergency stop switch is improperly

installed.

Shift lever is not in N position.

12. TROUBLESHOOTING

(2) Engine starts but immediately stops. Engine some

times stops while cruising.

Fuel

No gasoline in fuel tank.

There is gasoline -

in fuel tank.

iii

Water is mixed with

gasoline.

Vent knob is not open

or vent is clogged.

- Fuel filter is clogged.

I Air screw is open too

wide.

Idling speed is too slow.

- Carburetor vent is

clogged.

- Fuel pump is faulty.

Air in fuel pump.

Air enters through fuel

line connector.

Air enters through primer

bulb.

Engine overheats

Normal sparking

Water intake screens

arc clogged.

Spark plug is not of speci-

fied rating.

Water pump is faulty.

Thermostat is clogged.

Thermostat is faulty.

Water tube or passage

is clogged.

Exhaust gas is entering

cooling system.

13. SPECIFICATIONS

MODEL

BF35A

Dtscription Code

Long shaft: BLAG

Type

Overall length 27.0 in

(685 mm)

Overall width

14.6 in (370 mm)

Overall height

53.6 in ( 1,360 mm)

Transom height

L 20.5 in (520 mm)

Weight

L 203 lb (92 kg)

Rated power 35 HP (26. I kW)

Full throttle

range

4,600 - 5,600 ‘pm

Engine type

4 stroke OHC in-line 3 cylinder

Displacement

49.3 cu. in (808 cc)

Spark plug gap

0.024 - 0.028 in (0.6 - 0.7 mm)

(SC, SH) SAE low-30

13. SPECIFICATIONS

MODEL

Description Code

Type

Overall length

BF40A

Long shaft: BAYL

Extra long shaft: BAYU

R RT

28.6 in 27.0 in 27.0 in

(725 mm) (685 mm) (685 mm)

Overall width

Overall height

Transom height

Weight

Rated power

14.6 in (370 mm)

53.6 in (1,360 mm)

X 57.5 in (1,460 mm)

20.5 in (520 mm)

24.5 in (622 mm)

L 201 lb (91 kg) 198 lb (90 kg) 203 lb (92 kg)

212 lb (96 kg)

40 HP (29.8 kW)

Full throttle

range

5,000 - 6,000 ‘pm

Engine type

4 stroke OHC in-line 3 cylinder

Displacement

49.3 cu. in (808 cc)

Spark plug gap 0.024 - 0.028 in (0.6 - 0.7 mm)

Starter system

Electric starter

Ignition system C.D.1

Lubrication system Trochoid pump pressure lubrication

Specified oil Engine: API standard

(Fuel Efficient SG, SH) SAE

5w-30

Oil capacity

D.C. output

Cooling system

Exhaust system

Spark plugs

Fuel pump

Fuel

Tank capacity

Gear change

Steering angle

Transom angle

Gear case: API standard (CL-415)

SAE 90 outboard motor gear oil

Engine: 2.5 US qt (2.4 lit.)

Gear case: 0.53 US qt (0.5 lit.)

l2V-IOA

Water cooling with thermostat

Thru-hub

DR7EA (NGK),

X22ESR-U (NIPPONDENSO)

Diaphragm type

Automotive gasoline (86 pump octane)

6.6 US gal. (25 lit.)

Forward-Neutral-Reverse (dog type)

37.5” right and left

5 stages

(I l.5”, 15.5”, 19.5”, 23.5”, 27.5”)

13. ,SPECHFICATIONS

Overall length

27.0 in

(685 mm) (685 mm)

Ov,erall width

14.6 in (370 mm)

Full throttle

range

5,500 - 6,000 rpm

Engine type

Disolacement

4 stroke OHC in-line 3 cylinder

49.3 cu. in (808 cc)

Spark plug gap 1

0.024 - 0.028 in (0.6 - 0.7 mm)

Starter system

Electric starter

Ignition system

C.D.1

Lubrication system

Trochoid pump pressure lubrication

Specified oil Engine:

API standard

(Fuel Efficient SG, SH) SAE

5w-30

Gear case: API standard (GL-415)

SAE 90 outboard motor gear oil

Oil capacity

Engine: 2.5 US qt (2.4 lit.)

Gear case: 0.53 US qt (0.5 lit.)

D.C. outout I 12V-IOA

Cooling system

Exhaust system

Water cooling with thermostat

Thru-hub

Spark plugs

DR7EA (NGK),

X22ESR-U (NIPPONDENSO)

Fuel pump

Fuel

Diaphragm type

Automotive gasoline (86 pump octane)

Tank capacity

6.6 US gal. (25 lit.)

Gear change

Steering angle

Forward-Neutral-Reverse (dog type)

37.5” right and left

Transom angle

5 stages

(I 1.5”, 15.5”. 19.5’. 23.5’. 27.5”)

100

14. WARRANTY SERVICE

Owner Satisfaction

Your satisfaction and good will are

important to your dealer and to us. All

Honda warranty details are explained

in the Distributor’s Limited Warranty.

Normally, any problems concerning

the product will be handled by your

dealer’s service department. If you

have a warranty problem that has not

been handled to your satisfaction, we

suggest you take the following action:

Discuss your problem with a mem-

ber of dealership management.

Often complaints can be quickly

resolved at that level. If the prob-

lem has already been reviewed with

the Service Manager, contact the

owner of the dealership or the

General Manager.

In order to contact the Honda

Marine Customer Service Office,

you can write to:

American Honda Motor Co., Inc.

Honda Power Equipment Division

Customer Service Office

4475 River Green Parkway

Duluth, GA 30136-2565

Or telephone: (404) 497-6400

We will need the following informa-

tion in order to assist you:

- Your name, address, and telephone

number

- Product model and serial number

- Date of purchase

- Dealer name and address

- Nature of the problem

Your purchase of a Honda product is

greatly appreciated by both your deal-

er and American Honda Motor Co.,

Inc. We want to assist you in every

way possible to assure your complete

satisfaction with your purchase.

101

Current customer service contact information:

Your owner's manual was written to cover most of the questions you might ask about

your Honda. Any questions not answered in the owner's manual can be answered by

your Honda dealer. If your dealer doesn't have an immediate answer, they should be

able to get it for you.

If you have a difference of opinion with your dealer, please remember that each

dealership is independently owned and operated. That's why it's important to work to

resolve any differences at the dealership level. If the service personnel are unable to

assist you, please discuss your concerns with the dealer management such as the

Service Manager or the dealership's owner.

If you need to contact American Honda regarding your experiences with your Honda

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

American Honda Motor Co., Inc.

Marine Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, GA 30005-8847

Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST

When you write or call, please provide the following information:

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

• Model and complete serial number

• Date of purchase

• Name and location of the selling dealer

• Name and location of the servicing dealer (if different)

• A detailed description of your concerns

15. WIRING DIAGRAM

TILLER HANDLE TYPE

L -

n- DITm

102

15. WIRING DIAGRAM

REMOTE CONTROL TYPE

F==

15. WIRING DIAGRAM

r---------------’

XRTA type outboard

REMOTE

CONTROL,

POWER TRIM/TILT

TYPE

*= ;

HP I

-------------_

BF35A outboard I

104

16. INDEX

Anode Metal ...................................................................... 24

PRE-OPERATION CHECK ........................................ 34

MOTOR PROTECTION SYSTEM.. ........................... 66

Battery (not included) ........................................................ 84

Break-in Procedure ............................................................ 50

Choke Knob ....................................................................... 1 1

Choke/Fast Idle Lever.. ...................................................... 18

CLEANING AND FLUSHING ........................................ 73

COMPONENT IDENTIFICATION ................................... 8

CONTROLS & INSTRUMENTS (common) ................... 23

CONTROLS

GAS ASSISTED TILT TYPE ..................................... 22

TILLER HANDLE TYPE ........................................... 1 1

REMOTE CONTROL TYPE ...................................... 15

REMOTE CONTROL & POWER TRIM/TILT TYPE.. .. 20

Cooling System Indicator

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

Cruising

TILLER HANDLE TYPE ........................................... 52

REMOTE CONTROL TYPE ......................................

Emergency Starting ........................................................... 44

Emergency Stop Switch Lanyard

TILLER HANDLE TYPE ........................................... 13

REMOTE CONTROL TYPE

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

Engine Cover Removal/Installation

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

Engine Fuel Filter .............................................................. 87

Engine

Oil

Level check..

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

Change

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

Pressure and Overheat Warning System ................ 63

Over-Rev Limiter

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

Start Button ..................................................................

1 1

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

Fuel

Cap/Gauge/Vent/Knob

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

Level

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

.30

Line Connection ...........................................................

Tank and Filter .............................................................

Tank and Vent Knob

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

Fuel Recommendations .....................................................

3 1

Fuse Replacement

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

Gear Oil

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

Gear Shifting

TILLER HANDLE TYPE ...........................................

5 1

REMOTE CONTROL TYPE

...................................... 53

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

Ignition Switch

................................................................... 16

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

MAINTENANCE

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

SCHEDULE

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

Manual

Choke Knob .................................................................

Relief Valve

CONTROLS ........................................................... 22

OPERATION ......................................................... 60

MOTOR PROTECTION SYSTEM

.................................. 63

Neutral Release Lever

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

16., INDEX

Oil Pressure Indicator Light..

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

Oil Pressure Indicator Light/Buzzer

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

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

Over-Rev Limiter.. .............................................................

Overheat Indicator Light..

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

Overheat Indicator Light/Buzzer

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

Oxygenated Fuels

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

Power Tilt Switch (Motor Pan)

CONTROLS..

............................................................... 2 I

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

Power Trim Warning System

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

Power Trim Tilt Switch (remote control lever)

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

PRE-OPERATION CHECKS

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

Propeller..

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

9 I

Cotter pin.. ....................................................................

Remote Control

Friction Adjustment

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

Lever

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

SAFETY

.............................................................................. 6

INFORMATION..

.......................................................... 7

LABELS..

....................................................................... 6

Shallow Water Operation

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

Shift Lever

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

Spark Plug..

........................................................................ 83

SPECIFICATIONS..

.......................................................... 98

STARTING THE ENGINE

REMOTE CONTROL TYPE

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

4 I

TILLER HANDLE TYPE

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

Steering

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

Friction

Adjustment (common) .................................... 33

Stern bracket

PRE-OPERATION

CHECK ........................................ 34

STOPPING THE ENGINE

REMOTE CONTROL TYPE

...................................... 7 I

TILLER

HANDLE TYPE ........................................... 69

STORAGE

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

Submerged

Motor .............................................................. 92

Tachometer

........................................................................ 2 I

Throttle

Friction Knob

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

Grip

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

Opening

Indicator ........................................................ 12

Tilt Lever

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

Tilt Lock Lever

CONTROLS..

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

OPERATION

............................................................... 6 I

Tilting motor

GAS

ASSISTED TILT TYPE ..................................... 55

POWER

TRIM/TILT TYPE.. ...................................... 58

Tool Kit..

............................................................................ 34

Tool Kit and Spare

Parts .................................................... 76

Transom Angle Adjusting

Rod .......................................... 26

TRANSPORTING

............................................................. 72

Trim Meter

Controls

........................................................................ 2 I

Operation..

.................................................................... 59

Trim Tab

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

106

16. INDEX

Trim

Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Troubleshooting

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

Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1

Water Intakes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

WIRING

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

107

Honda BF40 - 50 Outboard Engines 40 and 50 hp 4 Stroke Motor Specs and Features

Product's Documents

Owner's Manuals BAYL-1000001 through 1999999

Specifications

Honda BF40 - 50 Questions and Answers