Honda Power Equipment BF40A Boat User Manual
Contents
1. LOCK LEVER WATER CHECK HOLE ENGINE OIL DRAIN SCREW FLUSH BOLT ANODE METAL EXHAUST 5 7 INSTALLATION It is your responsibility to choose a boat suitable for the engine horsepower Do not exceed the boat manufacturer s power recommenda tion Damage and injury may result 1 Installation Position Install at the stern at the center line of the boat 2 Installation Height For proper propeller depth and engine cooling the boat s transom height must match the motor s shaft length The short shaft motor re quires a transom height of about 15 in The long shaft motor requires a transom height of about 20 in Once the boat is in the water and loaded check proper motor depth by looking at the anti cavitation plate with the motor not running the plate should be about 100 mm 4 in below the surface of the water STERN CENTER ANTI CAVITATION PLATE During operation check to be sure the anticavitation plate remains under water at all times and that water flows from the water check hole Excessive imbalanced loading will affect the motor s water depth Loading too far forward will raise the motor out of the water reducing engine cooling Loading too much or too far rearward will push the motor deeper reducing performance CAUTION Insufficient water supply anticavitation plate out of the water may cause overheating that will damage the outboard motor 32. 0 06 0 14 mm 0 002 0 006 in EX 0 11 0 18 mm 0 004 0 007inl Spark plug gap 0 7 0 8 mm 0 028 0 031 ini Starter system Recoil starter Lubrication system Forced feeding of 01 under pressure with trochoid pump Specified oil Engine API Standard SF CC CD or SG 10W 30 Gear case API Standard GL 4 5 SAE 90 outboard motor gear oil Gil capacity Engine 0 55 7 0 58 U S qt Gear case 0 1 10 11 U S at Tank capacity 13 f 3 4 US gal Tilt angle 3 stage adjustment 30 45 and 70 Angle of rotation 45 both sides Dimensions 5 Model 525 x 1 005 x 340 mm 20 7 x 39 6 x 13 4 in Length X Height X Width 525 1 135 x 340 mm 20 7 x 44 7 x 13 4 in Height from stem bracket to S Model 445 mm 17 5 in anti cavitation plate L Model 572 mm 22 5 in Standard propeller 4 200 x 190 mm 7 25 32 X 7 31 64 im of blades diameter X pitch Dry weight S Model 27 kg 59 5 Ib L Model 27 5 kg 60 6 Ib 39 12 WIRING DIAGRAM TRANSISTORIZED MAGNETO ne ENGINE STOP BUTTON BLACK RED BLACK RED _ LJ 4 D BLACK RED BLACK RED B BLACK YELLOW 1 TW OPTIONAL KIT BLACK BLACK YELLOW DIL PRESSURE SWITCH INDICATOR LAMP FUSE RED RED RED 2 133 gt GREEN GREEN 1 TERMINAL 40 13 OPTIONAL PARTS GEAR OIL CHARGING AND LIGHTING COIL KIT KIT ENGINE COVER POWER PROPELLER
3. gZ TOOL BAG PHILLIPS SCREWDRIVER PLUG joey WRENCH SPARE 8 mm WRENCH EMERGENCY SPARK STARTER ROPE PLUG 26 Engine Oil Change Drain the oil while the engine is still warm to assure rapid and complete draining 1 Remove the engine cover Remove the drain bolt and filler cap and drain the oil Reinstall the drain bolt 2 Fill the crankcase with the recommended oil and check the oil level with the dipstick resting on the filler opening do not screw in Fill to the upper level mark 3 Reinstail the filler cap dipstick CAUTION Engine is a major factor affecting engine performance and service life Nondetergent oils and low quality engine oils are not recom mended because they have inadequate lubricating characteristics Oil capacity 0 55 f 0 58 U S qt DRAIN BOLT AR lt DIPSTICK UPPER LEVEL 0 55 f 0 58 U S qt LOWER LEVEL 0 4 0 42 U S qt CAUTION Used motor oil may cause skin cancer if repeatedly left in con tact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil NOTE Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station for reclamation Do not throw it in the trash or
4. CAUTION If water does not flow out or if steam comes out stop the engine Check to see if the cooling water inlet is obstructed Do not operate the engine until the problem has been corrected gt INTAKE OBSTRUCTED NORMAL FLOW WATER CHECK HOLE 6 If the choke was used push it in gradually as the engine warms up 4 A WARNING Exhaust contains poisonous carbon monoxide gas exposure can cause loss of consciousness and may lead to death Never run the engine in an enclosed area Be sure to provide adequate ventilation Be careful not to spill any fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before star ting the engine 16 Emergency Starting If the recoil starter is not working properly the engine can be started with the spare starter rope in the tool kit 1 Remove the engine cover 2 Wind the spare rope clockwise around the pulley and then pull it to start the engine CAUTION Keep clear of moving parts 3 Reinstall the engine cover CAUTION Do not operate without the engine cover Exposed moving parts could cause injury and water may damage the engine STARTER ROPE m 17 6 OPERATION CAUTION For the first 10 hours of operation run the outboard motor at law speed and avoid abrupt operation of the throttle 1 Gear Shifting The engine has 3 gears FORWARD NEUTRAL and REVERSE in dicato
5. Name and location of the selling dealer Name and location of the servicing dealer if different A detailed description of your concerns MEMO 43 44 3 Zv1510 000 9050715009009 OQX31 Zv1 B1C7 PRINTED IN JAPAN I I
6. Power Equipment Owners Manual Outboard Motot pri En ES Click here to save this XE manual to your computer 2 __ Eas EIE ESTER EH ESI Ee mu ___ Ee mamam s mamamanmi l SESS RRA nbn ERES ETUR ET _ tT ed ptt E TT Gmm I ES 6 SEES ERE ES moror co iro 1989 ___ ____ _ fe Thank you for purchasing a Honda Outboard Motor This manual covers operation and maintenance of the Honda BFSA Out board Motor All information in this publication is based on the latest product information available at the time of approval for printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the Outboard Motor and should remain with the Outboard Motor when it is sold Pay special attention to statements preceded by the following words DANGER Indica
7. Wipe up any spilled gasoline at once Disconnect the fuel tank line from the motor Remove the engine cover and remove the fuel filter NOTE Before removing the filter place clamps on the fuel tubes on each side of the filter to prevent fuel leakage Install the new fuel filter with the arrow mark pointing toward the carburetor NOTE Fuel flow will be impeded if the filter is installed backward 34 4 Remove the clamps used to close the fuel tubes Connect the fuel tank line to the motor Turn the fuel tank vent knob to the ON position pump the primer bulb and check for leaks NOTE If you find excessive water or sediment accumulated in the fuel filter inspect the fuel tank Clean the fuel tank if necessary The arrow marks indicate the fuel flow direction FUEL FILTER TUBE CLAMPS 35 9 TRANSPORTING STORAGE 1 Disconnect the fuel line and install the cap on the engine fuel inlet Firm ly close the fuel cap vent knob FUEL INLET IFUEL LINE CONNECTOR 2 Loosen the carburet container After draining retighten the drain screw AWARNING Be careful not to spill fuel Spilled fuel fuel vapor may ignite If any fuel is spilled make sure the area is dry before storing or transporting the motor Do not smoke or allow flames or sparks where fuel is drained or stored CAUTION In cold weather to prevent ice from forming inside the water pump pull the rec
8. Motor Attachment Attach the stern bracket to the transom and tighten the clamp screws 8 CAUTION While operating the boat check the tightness of the clamp screws occasionally Tie a rope through the hole in the stern bracket and secure the other end of the rope to the boat This will prevent accidental loss of the motor 4 Motor Angle cruising Adjust the motor so the axis of the propeller is parallel with the water surface CORRECT GIVES MAXIMUM PERFORMANCE 5 Motor Angle Adjustment If the propeller axis is not parallel with the water surface adjust by chang ing the adjusting rod position There are four adjusting stages 1 Push the adjusting rod in A twist upwards in B and pull out to remove 2 Inserting the rod in the proper hole twist it down to lock CAUTION To prevent damage to the motor or boat make sure the ad justing rod is locked INCORRECT CAUSES BOAT TO SQUAT INCORRECT CAUSES BOAT TO PLOW ADJUSTING R D ADJUSTING ROD TO CHANGE UNLOCKED POSITION TOLOCK LOCKED POSITION 9 4 PRE OPERATION CHECKS 1 Check the engine oil level CAUTION Engine oil is a major factor affecting engine performance and service life Nondetergent and low quality oils are not recommended because they have inadequate lubricating properties Running the engine with insufficient oil can cause serious engine damage Use Hon
9. 0 8 mm 0 028 0 031 in Correct as necessary by bending the side electrode 6 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 7 After the spark plug is seated tighten with a spark plug wrench to com press the washer C NOTE If installing nev spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer 8 Reinstall the engine cover CAUTION s The spark plug must be securely tightened An improperly tightened plug can become very hot and may cause engine damage Use only the recommended spark plugs or equivalent Spark plugs which have an improper heat range may cause engine damage PLUG WRENCH 1 0 7 0 8 mm t 0 028 0 031 inl 29 Cleaning and Flushing After each use in salt water or dirty water thoroughly clean and flush the outboard motor With Water Hose Joint 1 Wash the outside of the outboard motor with clean fresh water 2 Remove the flush bolt 3 Flush the cooling system using the water hose joint a Attach a hose from a fresh water HOSE JOINT water faucet to the hose joint f b Remove the propeller c Turn on the fresh water supply to the hose d Start the engine and run in neutral for at least 5 mi
10. FOR HEAVY LOAD Number of blades diameter x pitch 3 200 x 170 mm 7 25 32 x 6 11 16 in 41 14 WARRANTY SERVICE Owner Satisfaction Your satisfaction and goodwill are important to your dealer and to us All Honda warranty details are explained in the Distributor s Limited Warran ty any problems concerning the product will be handled by your dealer s service department 1 you have a warranty problem that has not been handled to your satisfaction we suggest you take the following action e Discuss your problem with a member of dealership management Often complaints can be quickly resolved at that level If the problem has already been reviewed with the Service Manager contact the owner of the dealership or the General Manager e f your problem still has not been resolved to your satisfaction contact American Honda Motor Co Inc P O Box 50 Gardena California 90247 0805 Telephone 213 604 2400 We will need the following information 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 After reviewing all the facts involved you will be advised of what action can be taken Please bear in mind that your problem will likely be resolved at the dealership using the dealer s facilities equipment and personnel so it is very important that your initial contact be
11. liters 2 9 Imp gal ESSENCE SEULEMENT 3 4 U S ga GESSUYER TOUTE ESSENCE RENVERSEE WARNING FLAMMABLE G A SOLI USE LOW LEAD OR REGULAR GASOLINE 86PUMP OCTANE DO NOT USE MIXTURE CAPACITY 13 LITERS 2 9 IMP GALLONS 3 4 U S GALLONS SAFE FILLING LEVEL 2 5cm 1tinch BELOW BOTTOM OF NECK BVVARIMINU HARMFUL OR FATAL IF SWALLOWED IF SWALLOWED DO NOT INDUCE VOMITING CALL PHYSICIAN INIMEDIATELY AVOID REPEATED OR PROLONGED CONTACT WITH SKIN OR BREATHING OF VAPOR DO NOT USE OR STORE NEAR HEAT SPARKS OR OPEN FLAME 2 REMOVE FROM BOAT FOR FILLING HONDA MOTOR CO LTD TOKYO JAPAN Honda Outboard Motors are designed to give safe and depend able service if operated according to instructions Read and understand the Owner s Manual before operating the Outboard Motor Failure to do so could result in personal injury or equipment damage To ensure safe operation Understand the operation of all controls and know how to stop the engine quickly READ THIS OWNER S MANUAL CAREFULLY Do not exceed the boat manufacturer s power recommendation and be sure the outboard motor is properly mounted Never permit anyone to operate the outboard motor without proper instruction Stop the engine immediately if anyone falls overboard Do not run the motor while the boat is near anyone in the water Exhaust contains poisonous carbon monoxide which can cause un consciousness and may lead
12. pin and the cotter pin to be sure they are secure and undamaged Check the stern bracket to be sure the motor is securely installed Check steering handle operation Make sure you have the too kit and spare parts with you 26 The anode metal for damage looseness or excessive corrosion The anode metal helps to protect the outboard motor form corrosion damage it must be exposed directly to the water whenever the motor is in use Replace the anode metal when it has been reduced to approximately one half of its original size CAUTION The possibility of corrosion damage is increased if the anode metal is painted over or allowed to deteriorate 12 5 STARTING THE ENGINE Fuel Line Connection CAUTION To prevent damage to the outboard from overheating never run the engine with the propeller out of the water 1 Connect the fuel line to the tank and outboard motor as shown Be sure the connectors are securely latched NOTE Position the fuel tank so the tank fuel line connector is no more than 1 meter 3 3 ft below the motor fuel line connector Do not place the fuel tank more than 2 meters 6 6 ft away from the motor Be sure that the fuel line is not kinked FEMALE FUEL LINE CONNECTOR TO MOTOR NNECTOR u 2 Open the fuel cap vent knob 2 to 3 turns 3 Squeeze and release the primer bulb until rt feels firm indicating that fuel has reached the motor Check for leaks Be careful no
13. produces fewer engine and spark plug deposits and extends the life of exhaust system components Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Use of a lower octane gasoline can cause persistent pinging or heavy spark knock metallic rapp ing noise which if severe can lead to engine damage CAUTION If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists consult your authorized Honda dealer Failure to do so is considered misuse and damage caused by misuse is not covered by Honda s Limited Warranty Occasionally you may experience light spark knock while operating under heavy loads This is no cause for concern it simply means your engine is operating efficiently Fuel tank capacity 13 3 4 U S gal FUEL FILLER CAP FUEL GAUGE After refueling be sure to tighten the fuel tank cap firmly Gasoline is extremely flammable and is explosive under certain conditions 11 Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline ts stored Do not overfill the tank there should be no fuel in the filler neck After refueling make sure the tank cap is closed properly and securely Be careful not to spill fuel when refueling Sp
14. to death Never run the outboard in a clos ed garage or confined area Gasoline is extremely flammable and is explosive under certain condi tions Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks where the engine is refueled or where gasoline ts stored Do not overfill the fuel tank After refueling make sure that the fuel tank cap is closed properly and securely Be careful not to spill any fuel while refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure that the area is dry before starting the engine Do not remove any guards labels shields covers or safety devices they are installed for your safety 2 COMPONENT IDENTIFICATION ENGINE COVER SHIFT LEVER CHOKE KNOB THROTTLE FRICTION BONDA KNOB _ a TILT LEVER aP FUEL LINE CONNECTOR MALE ABJUSTING ROD ANTI CAVITATION PLATE WATER INTAKE PROPELLER 1 FUEL GAUGE FUEL FILLER CAP SPARE CONTAINER come 3 FUEL TANK os TOOL KIT PRIMER BULB AY c 2 EEL LINE FUEL LINE CONNECTOR FEMALE 8 ENGINE STOP BUTTON SPARK PLUG OIL FILLER CAP FHROTTLE GRIP STARTER GRIP OIL PRESSURE INDICATOR LAMP ENGINE COVER STEERING FRICTION BOLT amm CLAMP SCREW STERN BRACKET GEAR OIL LEVEL BOLT a gt x GEAR DRAIN BOLT 2
15. with the dealer Your purchase of a Honda product is greatly appreciated by both your dealer and American Honda Motor Co Inc We want to assist you in every way possible to assure your complete satisfaction with your purchase 42 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
16. LE GRIP THROTTLE FRICTION KNOB TO DECREASE FRICTION 1 2 Se 3 TO INCREASE FRICTION 20 n lt 4 Tilting the Motor Tilt the motor to prevent the propeller and gear case from hitting bottom when the boat is beached or stopped in shallow water 1 Stop the engine and put the shift lever into NEUTRAL 2 Raise the engine to either the 309 45 or 70 tilt position CAUTION Do not use the throttle grip to tilt the outboard motor SHIFT LEVER NEUTRAL When not in use 457 70 3 To return the engine to the normal RUN position pull the tilt lever toward you until it stops tilt the engine up slightly then lower the engine slowly TILT LEVER 21 CAUTION To avoid damaging the motor use the utmost care when mooring the boat especially when its motor is titted up Don t allow the motor to strike against the pier or other boats e x CAUTION To avoid damaging the motor never use it as a handle for lift ing or moving the boat Trailering When trailering or transporting the boat with the motor attached itis recommended that the motor remain in normal running position with the steering friction bolt tightened securely CAUTION Do not trailer or transport the boat with the motor in the tilted position The boat or motor could be severely damaged if the motor drops The motor should be trailered in the normal running position if the
17. al corrosion 9 Store the outboard motor in a clean dry area NOTE Before Dring described on pages 30 31 CORRECT ush and lubricate the outboard motor as INCORRECT 37 10 TROUBLESHOOTING Engine Will Not Start ee N Is the shift lever in neutral 5 there fuel in the fuel tank Is the fuel cap knob turned to ON _ 15 the fuel system primed by squeezing the bulb 15 fuel reaching the carburetor Loosen the carburetor drain screw to see if there is fuel in the carburetor float bowl If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Spilled fuel or fuel vapor may ignite 6 15 the spark plug firing a b e d Remove and inspect the spark plug Clean and dry the plug and check the electrode gap 29 Install the spark plug in cap and ground the side electrode to any engine ground Pull the recoil starter briskly and see if the plug sparks If the spark plug is OK reinstall it and try to start the engine Engine Overheats 1 Are the water intake holes clogged 2 Is the thermostat faulty 38 11 SPECIFICATIONS MODEL Description Code 5 Model BADS L Model BADL Output 5 0 horsepower Maximum Recommended full throttle range 4 000 5 000 rpm Engine type 4 stroke vertical single cylinder type Displacement 127 cc 7 7 cJ in Valve tappet clearance
18. da 4 stroke oil or equivalent high detergent premium quality motor certified to meet or exceed U S automobile manufac turers requirements for Service Classification SF CC CD or SG Motor oils classified SF CC CD or SG will show this designation on the 3 20 i0 0 10 20 30 40 C container SAE 10W 30 is recommended for general all temperature use Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range 1 Position the outboard motor vertically and remove the engine cover 2 Remove the dipstick and wipe with a clean rag 3 Reinsert the dipstick and check the oil level with the dipstick resting on the filler opening do not screw in If the oil level is low to the upper level mark DIPSTICK capacity 0 55 f 0 58 U S at ENGINE COVER LOCK LEVER UNLOCK UPPER LEVEL 0 55 f 0 58 U S qt LOWER LEVEL 0 4 0 42 U S qt 10 2 Fuel Level Check the fuel gauge and refill the tank if the fuel level is low NOTE Open the vent knob before removing the fuel filler cap When the vent knob is firmly closed the cap will be difficult to remove Your engine is designed to use any gasoline that has a pump tane number 8 of 86 or higher or that has a research octane number of 91 or higher Gasoline pumps at service stations normaliy display the pump octane number We recommend that you use unleaded fuel because it
19. hanical damage such as bent connecting rods If the engine binds when crank ed do not attempt to run the motor until it has been repaired 5 Pour a teaspoon of engine oil into the spark plug hole then pull the recoil starter several times to lubricate the inside of the cylinder Reinstall the spark plug 6 Attempt to start the engine f the engine fails to start remove the spark plug clean and dry the electrode then reinstall the spark plug and attempt to start the engine again e If the engine starts and no mechanical damage is evident continue to run the engine for 1 2 hour or langer be sure the water jevel is at least 4 inches above the anti cavitation plate 7 As soon as possible take the motor to a Honda outboard motor dealer for inspection and service 18 2 d n LEI Yi Fuel Filter Replacement The fuel filter is located between the fuel pump and the carburetor Water or sediment accumulated in the fuel filter can cause loss of power or hard starting To prevent engine malfunction replace the fuel filter regularly SERVICE PERIOD Every 200 operating hours or every one year WARNING Gasoline is flammable and is explosive under certain conditions Do not smoke or allow flames or sparks near the outboard motor while draining fuel Always work in 2 well ventilated area Be sure that any fuel drained from the outboard motor is stored a safe container
20. high altitude the standard carburetor air fuel mixture will be excessive ly rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw If you always operate the outboard motor at altitudes higher than 6 000 feet above sea level have your authorized Honda Outboard Motor dealer per form these carburetor modifications Even with suitable carburetor jetting engine horsepower will decrease ap proximately 3 5 for each 1 000 foot increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modifica tion is made CAUTION Operation of the outboard motor at an altitude lower than the carburetor is jetted for may result in reduced performance overheating and serious engine damage caused by an excessively lean air fuel mixture 24 8 MAINTENANCE Periodic maintenance and adjustment are important to keep the motor in the best operating condition Inspect or service as scheduled below Shut off the engine before performing any maintenance If the engine must be run make sure the area is well ventilated Never run the engine in an enclosed or confined area Exhaust contains poisonous carbon monoxide gas exposure can cause loss of consciousness and may lead to death CAUTION f the engine must be run make sure there ts water at least 4 inche
21. illed fuel or fuel vapor may ignite any fuel is spilled make sure the area is dry before starting the engine Avoid repeated or prolonged contact with skin or breathing of vapor KEEP OUT OF REACH OF CHILDREN GASOLINES CONTAINING ALCOHOL If you decide to use a gasoline containing alcohol gasohol be sure its oc tane rating is at least as high as that recommended by Honda There are two types of gasohol one containing ethanol and the other containing methanol Do not use gasohol that contains more than 10 ethanol Do not use gasoline containing methanol methyl or wood alcohol that does not also contain cosolvents and corrosion inhibitors for methanol Never use gasoline containing more than 5 methanol even if it has cosolvents and corrosion inhibitors NOTE Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete Before buying fuel from an unfamiliar station try to find out if the fuel contains alcohol if it does confirm the type and percentage of alcohol used If you notice any undesirable operating symptoms while using a gasoline that contains alcohol or one that you think contains alcohol switch to a gasoline that you know does not contain alcohol 3 Check the following ttems Check the propeller the shear
22. nutes Without Water Hose Joint HOSE 1 Wash the outside of the outboard motor with clean fresh water 2 Remove the propeller 3 Stand the motor in a suitable container of water The water level must be at least 4 inches above the anti cavitation plate 4 Start the engine and run slowly for at least 5b minutes ANTI CAVITATION PLATE AWARNING For safety the propeller must be removed sure the outboard motor is securely mounted and do not leave it unattended while running Keep children and pets away from the area and stay clear of moving parts during this procedure CAUTION Running the engine without water can cause serious engine damage due to overheating Be sure that water flows from the water check hole while the engine is running not stop the engine and determine the cause of the problem 30 Lubrication Wipe the outside of the engine with a cloth dipped in ail Apply marine anti corrosion grease to the following areas NOTE Apply anti corrosion oil to pivot surfaces where grease cannot penetrate ENGINE COVER LOCK LEVER THROTTLE CABLE AND PIVOT SHIFT SHAFT AND PIVOT TILT LEVER REVERSE LOCK CLAMP SCREWS LEVER PROPELLER SHAFT 31 Shear Pin Change A shear pin is used to protect the propeller and drive mechanism fro damage when the propeller strikes an obstruction 1 Remove the cotter pin the propeller cap and the propeller 2 Remove the broken
23. oil starter several times to flush the water out DRAIN SCREW 36 3 To carry hold the motor by the carrying handle or hold by the carrying handle and engine cover lock lever as shown here Do not carry by the engine cover lt SS 4 Transport and store the motor either vertically or horizontally as shown below with the steering handle raised Vertical transport or storage Attach the stern bracket to a stand CAUTION Any other transport or storage position may cause damage or 011 leakage 5 Tilt up the outboard motor remove the plug cap pull the recoil starter several times and completely drain the cooling water CAUTION the outboard motor is placed on its side without completely draining the cooling water immediately after operation water may enter the engine through the exhaust port Be sure to drain the cooling water before placing the outboard motor on its side Be careful not to touch the spark plug wire while pulling the starter grip 6 Change the engine oil 7 Remove the spark plug and pour about a tablespoon of clean engine oll into the cylinder Crank the engine several revolutions to distribute the oil then reinstall the spark plug 8 Slowly pull the starter grip until resistance is felt At this point the piston is coming up on its compression stroke and both the intake and exhaust valves are closed Storing the engine in this pasition will help to protect it from intern
24. pour it on the ground 27 Gear Oil Check Change Oil level check Check the oil level when the engine is in the vertical position Remove the level and see if oil flows out If no oil comes out fill through the drain bolt hole until the oil starts to flow out through the level hole 11 there is water in the oil the water will flow out first when the drain bolt is removed or the oil will be a milky color Oil change Remove the level bolt and drain bolt to drain the oil Inject oil through the drain bolt hole until it starts flowing out through the level bolt hole Reinstall and tighten the level bolt and drain bolt securely CAUTION If water is detected in the oil the unit should be inspected by an authorized Honda outboard motor dealer Recommended Oil API standard GL 4 or GL 5 SAE 90 outboard motor gear oil Oil capacity 0 1 0 11 U S qt GEAR OIL LEVEL BOLT GEAR OIL DRAIN BOLT Starter Rope Check Check the starter rope every 6 months or after every 100 hours of out board motor operation Replace the rope if it is frayed 23 Spark Plug Service Recommended spark plug BPR5ES W1GEPR U Remove the engine cover Remove the spark plug cap Use the wrench supplied in the tool kit to remove the spark plug Visually inspect the spark plug Discard it if the insulator is cracked or chipped Measure the plug gap with a feeler gauge The gap should be 0 7
25. r at the base of the gear shift lever aligns with the letter F N or Ron the engine case to show the gear that has been selected Turn the throttle grip to SLOW to decrease engine speed before moving the gear shift lever CAUTION When operating in reverse proceed with caution to avoid hit ting any underwater obstruction with the propeller NOTE The throttle mechanism is designed to limit throttle opening in REVERSE and NEUTRAL The throttle can be opened to FAST only in FOR WARD gear NEUTRAL THROTTLE GRIP SHIFT LEVER 7 FORWARD 18 2 Steering To turn to the right swing the steering handle to the left To turn to the left swing the handle to the right 4 rr For smooth steering adjust the steering friction bolt so that a slight drag is felt when turning STEERING FRICTION BOLT oes DECREASE FRICTION y 4 9 TO INCREASE FRICTION Y 19 3 Cruising FORWARD With the shift lever in the forward position F turn the throttle grip toward FAST to increase speed For normal cruising open the throttle about 3 4 To hold the throttle at a steady set ting turn the throttle friction knob clockwise To free the throttle grip for manual speed control turn the friction knob counterclockwise SHIFT LEVER NOTE For best performance pas sengers and equipment should be distributed evenly to balance the boat THROTT
26. re is in sufficient road clearance in this position then trailer the motor in the tilted position using a motor support device such as a transom saver bar or remove the motor from the boat 22 5 Battery Charging and Lighting Optional parts DC receptacle provides 12V 40W current for 12V battery charging and lighting The circuit is protected by a 5A fuse that is accessible by removing the engine cover An electrical plug for the DC receptacle is supplied with your motor Wire your charging or lighting cord to this plug Batteries produce explosive gases Keep sparks flames and cigarettes away To prevent the possibility of creating a spark near the bat tery connect the charging cords first to the battery then to the outboard motor and disconnect the charging cords first at the outboard motor CAUTION Connect the positive battery terminal to the positive charging cord Do not reverse the charging cords or serious damage to the outboard motor s charging circuit and or battery may occur When not in use cover the DC receptacle with the rubber cover to keep it dry and clean DC RECEPTACLE FUSE HOLDER FUSE RUBBER COVER 23 7 STOPPING THE ENGINE 1 Turn the throttle grip to slow and move the shift lever to NEUTRAL NEUTRAL 2 THROTTLE GRIP Oo SHIFT LEVER 2 Push the stop button until the engine stops running STOP BUTTON High altitude operation At
27. s above the anti cavitation plate otherwise the water pump may not receive sufficient cooling water and the extension case will overheat To maintain cooling system efficiency flush the outboard motor with fresh water after each use in salt water or dirty water e Use only genuine HONDA parts or their equivalent The use of replace ment parts which are not of equivalent quality may damage the motor REGULAR SERVICE PERIOD ITEM Performed at every indicated month or operating hour intervals whichever comes first Engine ail Check leval Gear case oil Check for water contamination Lubrication Fue tank and filter Fuel strainer Check NOTE 11 Lubricate more frequently when used salt water 2 These iterns should be serviced by an authorized Honda outboard motor 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 2b Tool Kit and Spare Parts The following tools and spare parts are supplied with the outboard motor for maintenance adjustment and emergency repairs The tool kit and ot bottle are located in a compartment on the fuel tank Spare shear pins and cotter pins are located inside the engine compart ment above the stern bracket COTTER PINS Tool Kit 2j d5 10x 12 mm WRENCH FLAT SCREWDRIVER PLIERS
28. shear pin and replace it with a new one 3 Install the propeller then install the propeller cap finger tight 4 Install anew cotter pin and spread the ends as shown in the illustration PROPELLER SPARE SHEAR PINS AND COTTER PINS COTTER 32 Servicing a Submerged Motor A submerged motor must be serviced immediately after it is recovered from the water in order to minimize corrosion If there is a Honda outboard motor dealership nearby take the motor im mediately to the dealer If you are far from a dealership proceed as follows 1 Remove the engine cover and rinse the motor with fresh water to remove salt water sand mud etc 2 Loosen the carburetor drain screw p 36 drain the contents of the car buretor into a suitable container then retighten the drain screw 3 Change the engine oil If there was water in the engine crankcase or the used engine oil showed signs of water contamination then a second engine oil change should be performed after running the engine for 1 2 hour 4 Remove the spark plug While pressing the engine stop button pull the recoil starter several times to completely expel water from the cylinder CAUTION When cranking the engine with an open ignition circuit spark plug removed from the ignition circuit keep the engine stop button depress ed to prevent electrical damage to the ignition system f the motor was running when it submerged there may be mec
29. t to spill any fuel Spilled fuel or fuel vapor may ig nite If any fuel is spilled make sure the area is dry before starting the engine NOTE It is not necessary to use the primer bulb while the engine is running VENT KNOB PRIMER BULE 13 Starting Exhaust contains poisonous carbon monoxide gas exposure can cause loss of consciousness and may lead to death Never run the engine in an enclosed area Be sure to provide adequate ventilation CAUTION Damage to the water pump engine components and exhaust system may occur if the motor is operated while the propeller is out of the water 1 Put the shift lever in NEUTRAL NEUTRAL OM CE SHIFT LEVER 7 2 temperatures below 20 C 68 F pull the choke knob out al CHOKE KNO 14 3 Pull the starter rope slowly until resistance is felt then pull briskly CAUTION Do not allow the starter grip to snap back against the housing return it gently by hand to prevent damage to the starter Do not pull the starter grip while the engine is running as that may damage the starter 4 The oil pressure indicator lamp should be on while the engine is running If the lamp goes off stop the engine immediately check the engine oil level and inspect the engine for oil leaks OIL PRESSURE INDICATOR LAMP S 15 5 After starting be sure water is flowing out of the water check hole
30. tes severe personal injury or death will result if in structions are not followed Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about the Outboard Motor consult an authorized Honda dealer CONTENTS INN PNA 51 ec 41 14 WARRANTY eee 42 1 SAFETY SAFETY LABEL LOCATIONS Read all safety instructions before using the outboard motor AWARNING TO AVOID PERSONAL INJURY READ MANUAL CAREFULLY BEFORE OPERATION PLACE TRANSMISSION IN NEUTRAL BEFOHE STARTING DO NOT OPERATE WITH ENGINE COVER REMOVED A CAUTION TO AVOID DAMAGE THE MOTOH a CHECK OIL LEVEL BEFORE STARTING a ANTI CAVITATION PLATE MUST BE SUBMERGED IN WATER BEFORE OPERATION a FLUSH THE SYSTEM THOROUGHLY WITH FRESH WATER AFTER EACH USE IN SALT WATER s PULL STAATER LIGHTLY UNTIL RESISTANCE IS FELT THEN PULL BRISKLY WHEN STORING TURN HANDLE UP AND PLACE MOTOR IN POSITION OR B I y Wen OU E Z Y DIL FILLER 18 IN THE COVER 011 SAE 100 30 0 55 z NEM m ADD OIL UP TO THE UPPER 26 8 1 LEVEL IF NECESSARY B WIPE OFF SPILLED GASOLINE COMPLETELY GASOLINE ONLY 13
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