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Honda Power Equipment BF40A/50A Boat User Manual

1. 4 2 0 1 66011 arent ptr 65 Power Trim Warning System 2 22 4 221 70 Power Trim Tilt Switch 1 leaena GE PRE OPERATION 30 Propeller ae ta csaessnepegeeeeegerss 98 Cotter 2 1 100 res 35 Remote Control Friction Adjustment 36 LEVEL raves nenne raumens 17 Shallow Water Operation o 0 cccececsseeseneeee eene ener nenas natara naga 72 Shift Lever CMM t3 Spark Plug 91 SPECIFICATIONS 105 STARTING THE ENGINE REMOTE CONTROL TYPE 22222 44 TILLER HANDLE 40 112 22 55 Friction Adjustment eee mene 36 Stem bracket PRE OPERATION CHECK 37 STOPPING THE ENGINE REMOTE CONTROL TYPE essem 76 TILLER HANDLE 74 STORAGE ERR 101 Submerged Motor sss rettet nne 99 Tachomet
2. n 23 CONTENTS Tachometer eese reme anna na Manual Relief GAS ASSISTED TILT TYPE Tilt Lever CONTROLS COMMON EL Tilt Lock Lever Trim Tab Anode Metal Cooling System Indicator Waiter ntakes Transom Angle d Rod Fuel 2 ent Knob Over Rev Limiter Engine Cover Removal Installation Engine Oil aus eere Puck Level esececeeeeeteerena nenne eed eed ae taa Fuel Recommendations 2 4 2 4 Oxygenated Fuels Propeller and Cotter Pin Steering Priction Adjustment common SM Remote Control Friction Adjustment Other Checks Stern 2 2 4 4 4 Fool Kit Anodes ww Fuel Tank and Vent Knob CONTENTS Fuel Line Connection escena 38 STARTING THE ENGINE TILLER HANDLE TYPE 40 STARTING THE ENGINE REMOTE CONTROL TYPE 44 Emergency Starting Troubleshooting Starting Problems 52 1 Procedure TEL TILLER HANDLE TYPE Gear ME m 54 Steering pomi 55 Cruising 55 REMOTE CONTROL Cruising abkbtdhcRdhcd ae Tilting
3. nnne nnne 47 Emergency Stop Switch Lanyard TILLER HANDLE 2 2 2222 2 4 4 2 ES REMOTE CONTROL 19 Engine Cover Removal Installation seems 30 Engine Fuel Filter eene ennemi 94 Engine Level Check rran 31 CHAMBRE B Pressure and Overheat Warning System 68 Over Rev Limiter entente rere arta eire 29 Start Button BRANI 13 SHOP Switch 15 Fuel Cap Gauge V ent Knob 49 IA T2 MEME 32 Line Connection ennt nan nnnm memet nnn 38 Tank and Filter eere nennen nennt nad 96 Tank and Vent 38 Fuel Recommendations sees ecce nere nnne 33 Fuse Replacement scscccssccccsseccesssessecessseeesssessessnenensnoensnnseraaensesnes 97 Gear EEMIMMMMMMMMMEMMMMMMMMEMMMM tm 89 Gear Shifting TILLER HANDLE 2 0 2 0 0 000 54 REMOTE CONTROL TYPE 229 High Altitude Operation 73 Ignition sereni renean nenas 18 Lubricati
4. plate and attached to the Number for your reference Refer to the right stern bracket The Engine Serial Product Identification Number when Number is stamped on the cylinder ordering parts and when making block under the starter motor which 15 or warranty inquiries see page located in the front of the engine 107 Product identification number Engine serial number IMPORTANT SAFETY INFORMATION 7 SAFETY LABEL LOCATIONS 9 10 TILLER HANDLE TYPE Engine Start Button esee nenne 13 5mit LOYO e ostiis incite Td Choke 2 2 2 2 13 Bl i iiim M Hn 14 Throttle Opening Indicator I4 Throttle Friction Knob 14 Engine Stop Switch 19 Emergency Stop Switch Lanyard 15 Oil Pressure Indicator Light 16 Overheat Indicator 16 REMOTE CONTROL TYPE Remote Control Lever 2 107 Neutral Release Lever 18 Ignition 18 Emergency Stop Switch Lanyard Choke Fast Idle Lever m 20 Manual Choke Knob REA D Oil Pressure Indicator Light Buzzer Overheat Indicator Light Buzzer 2l POWER TRIM TILT TYPE Power Trim Tih iue abuti inest aus 22 Power Tilt Switch motor pan sse 22 Trim Meter
5. GREEN The green oil pressure indicator light The red overheat indicator light turns turns OFF and the buzzer sounds ON and the buzzer sounds when the when the oil level is low and or the engine cooling system is faulty The engine lubrication system is faulty engine speed slows down gradually The engine speed slows down gradual ly 21 3 CONTROLS POWER TRIM TILT TYPE Power Trim Tilt Switch Power Trim Press the power trin tilt switch on the remote control lever remote control type to adjust the motor trim angle of 0 to 20 Io maintain proper boat trim The power swHch located on the remote control lever remote type can be operated while the boat is under way or while stopped By using the power trim tilt switch the operator can change the trim angle of the motor to achieve maximum boat accel eration speed stabiltty and maintain optimum fuel consumption Power Tilt Press the power trim tilt switch on the remote control lever remote control type to adjust the motor tilt angle of 20 to 60 Bv 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 22 POWER TRIM TILT SWITCH remote control type On the tiller handle type the power trim tilt switch is the optional part The power trim Hilt switch is available on your authorized Honda Marine dealer CONTROL LEVER
6. 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 WTANTEB EWTTUM 108 e 15 WIRING DIAGRAM REMOTE CONTROL TYPE 109 15 WIRING DIAGRAM REMOTE CONTROL POWER TRIM TILT TYPE e eee 110 16 INDEX Anode Metal M 26 PRE OPERATION CHECK MOTOR PROTECTION SYSTEM eee 71 Battery not included 92 Break Procedure 53 Choke Knob 13 Choke Fast Idle Lever eene rne 20 CLEANING AND FLUSHING 78 COMPONENT IDENTIFICATION 10 CONTROLS COMMON 25 GAS ASSISTED TILT TYPE 25 TILLER HANDLE TYPE nennen nnnm nos 13 REMOTE CONTROL TYPE eren 17 POWER TRIM TILT TYPE 22 Cooling System Indicator eese eerte tnter 27 Cruising TILLER HANDLE 1 2 55 REMOTE CONTROL 58 Emergency Starting
7. 81 10 MAINTENANCE The U S Clean Air Acts EPA regulations require all manufactur ers to furntsh written instructions describing the operation and mainte nance of emission control systems The following instructions and proce dures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission contro system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems 82 e Alterations that would cause the engine to operate outside its design parameters n m nle Problems That May Affect Emis sions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer e Hard starting or stalling after starting Rough idle Misfiring or backfinng under load Afterburning backfiring e Black exhaust smoke or high fuel consumption 10 MAINTENANCE Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the o
8. Excessive trim tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over revving Excessive trim tilt angle can also damage the water pump 3 CONTROLS POWER TRIM TILT TYPE 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 engine for example wide open throttle under certain conditions propeller thrust may override the power trim hydraulics and cause the engine to return to the transom angle adjusting 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 operator can change the tilt angle of the motor fer shallow water operation beaching launching from a trailer or mooring Power Tilt Switch motor pan gt POWER TILT SWITCH The power tilt switch located on the motor pan is a convenience switch for tilting the motor for trailering or preforming outboard maintenance This power tilt switch should only be oper ated with the boat is 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 outboard motor Refer to the trim meter when using the power trim tilt switch to achieve proper boat performance 23 3 CONTROLS POWER TRIM TILT TYPE Tachom
9. STOP SWITC STOP SWITCH H 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 STARTING THE ENGINE EMERGENCY STARTING ON IGNITION KEY EMERGENCY ENGINE STOP SWITCH d ifr id EMERGENCY ast 5 If your outboard motor is remote control type turn the ignition key to the ON position Engage the emer gency stop switch clip located at 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 CHOKE KNOB TILLER HANDLE TYPE If the engine is cold or the ambient temperature is low pull the manual choke knob located on the front of the outboard motor 49 _ 5 STARTING THE ENGINE EMERGENCY STARTING ENGINE START SYMBOL CHOKE FAST IDLE LEVER 21 POINTER lt THROTTLE GRIP CHOKE KNOB REMOTE CONTROL TYPE TILLER HANDLE TYPE REMOTE CONTROL TYPE It should only be necessary to pull the 7 On the tiller handle type align the engine 1 or 2 times with the choke knob engine start symbol amp on the out throttle grip with the painter on the tiller handle On the remote control type lift the ch
10. check to see if the green engine oil pressure indicator light turns ON Stop the engine if the oil pressure indicator light does not tum ON Check the engine oil level ee page 31 If the oil level is normal and the oil pressure indicator light does not tum ON contact your closest authorized Honda Marine dealer 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 Emergency Starting FRONT 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 6 x 25 mm BOLTS WASHER FLYWHEEL COVER 2 Remove the four 6 x 25 mm bolts and the three washers then remove the flywheel cover Do not lose the washers 47 5 STARTING THE ENGINE EMERGENCY STARTING j N f neutra SHIFT LEVER TILLER HANDLE TYPE 3 Depending on what type of out board motor you havc move the shift lever or the control lever to the N neutral position 48 N neutral REMOTE CONTROL TYPE ENGINE STOP SWITCH EMERGENCY STOP SWITCH LANYARD SPARE EMERGENCY EMERGENCY
11. CONTROLS COMMON Cooling System Indicator COOLING SYSTEM INDICATOR The cooling system is monitored here to make sure cooling water is circulating through the engine Water Intakes ge m ES gt WATER INTAKES The engine cooling water is drawn into the water pump through these water intakes 27 3 CONTROLS 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 stern bracket Pushin and turn the transom angle adjusting rod up to remove To install insert into the proper hole and turn down to lock After installation puli the transom angle adjusting rod out ward to be sure it is locked in place Start with the transom angle adjusting rod n the hole closest to the boat tran 28 TRANSOM ANGLE TOCHANGE ADJUSTING ROD UNLOCKED POSITION i TO 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 tbe 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 C
12. 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 Cui CHOKE KNOB THROTTLE GRIP 3 Align the engine start symbol 4 When the engine is cold or ambient NOTICE the throttle grip with the temperature is low pull the choke 20 not press the start but pointer on the tiller handle knob This can damage the starter motor 5 Press the start button and start the and flywheel engine The starter motor con sumes a large amount of current Do not run it continuously for more than 5 seconds at atime If the engine does not start within 5 sec onds wait at least 10 seconds before using the starter motor again 41 5 STARTING THE ENGINE TILLER HANDLE TYPE CHOKE KNOB THROTTLE 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 42 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 wate
13. Precautions Make sure the engine 15 off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventila tion whenever you operate the engine Burns from hot parts Let the engine cool before touch ing Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonfiam mable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from al fuel related parts Remember that an authorized Honda Marine dealer knows your outboard motor best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for rcpair and replacement EMISSION CONTROL SYSTEM INFORMATION Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocar bons and oxides of nitrogen is very important because under certain conditions they react to form photo chemical smog when subjected to sunlight Honda utilizes lean carburetor settings and other systems to reduce the emis sions of oxides of nitrogen and hydro carbons
14. 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 Flush the outboard motor in the neutral position only 6 Tum on the fresh water supply to the flush kit coupler Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine 9 CLEANING AND FLUSHING 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 10 Remove the sealing washer from the flush kit coupler and install the COOLING SYSTEM INDICATOR 5 j sealing washer on the wash plug 7 Start the engine Monitor the cool WATER INTAKES If tape was used to cover the three water ing system indicator Stop the intakes in step 7 remove the tape now engine if water does not come out of the cooling system indicator and 11 Install the wash plug into the gear check the fresh water supply If the case securely fresh water supply is insufficient it may be necessary to temporatily cover the three water intakes with duct tape 79 10 MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free operation It will also help reduce pollution Improper mainte nance or failure to correct a problem before operation can cause a malfunct
15. make sure the area is dry before storing or trans potting the motor Do not smoke or allow flames or sparks where gasoline is drained or stored A Gasoline is extramaly 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 DRAIN 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 Drain the 1 and 2 carburetors in the same manner using the 3 car buretor drain hose 2 CARBURETOR DRAIN SCREW 1 CARBURETOR DRAIN SCREW 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 101 I1 STORAGE Fuel Tank Outboard Motor Position VENT KNOB CASE PROTECTORS FUEL CAP 1 Close the fuel cap vent knob Transport and store the motor either Horizontal transport or storage 2 Disconnect the fuel coupling from the vertically or horizontally as shown Rest the motor on the case protectors outboard motor refer to page 38 38 above Store thz outboard motor in well ventilated area free from direct NOTICE Improper transport or sunlight and humidity storage can damage the motor or caus
16. plug hole until it starts flowing out through the level plug hole Use new sealing washers and reinstall the levet plug first and then the drain plug securely GEAR OIL BOTTLE OIL CAPACITY gear oil bottle 15 recommended 10 0 53 US qt 0 5 lit All 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 holc 3 Use new sealing washers and rein stall the level plug and drain plug securely 10 MAINTENANCE Spark Plugs To ensure proper engine operation the a 0 024 0 028 in spark plugs must be properly gapped Qi 0 6 0 7 mm i ee and free of deposits Check replace interval After first 20 hours then every D 200 hours Refer to the maintenance e schedule page 85 E ara DA SPARK PLUG Recommended spark plug SPARK WRENCH PLUG CAPS X22ESR U DENSO Use only the recommended spark 3 Disconnect the spark plug caps 6 Measure the plug gaps with a spark plugs or equivalent from the spark plugs plug gap gauge 4 Use the wrench and screwdriver The gaps should be 0 024 0 028 in Sp rk plugs which have supplied in the tool kit to remove 0 6 0 7 mm Correct as necessary an improper heat range may cause the spark plugs by carefully bending the side elec engine damage 3 Check the spark plugs R
17. power trim tilt switch is the optional part The power trim tilt switch is available on your authorized Honda Marine dealer 55 6 OPERATION TILLER HANDLE TYPE THROTTLE GRIP With the gearshift lever in the F for ward position tum the throtle grip toward the FAST mark to increase speed For optimum fuel economy limit throttle opening to 2 3 56 F forward GEARSHIFT LEVER THROTTLE FRICTION KNOB RELEASE To set the throttle at a steady speed tum the throttle friction knob clockwise release the throttle grip for manual speed contro turn the friction knob counterclockwise 6 OPERATION REMOTE CONTROL TYPE Gear Shifting neutral R 30 reverse N F neutral forward M i MAXIMUM OPENING While pulling up the neutral release Moving the control lever further from The control lever will not move unless lever move the control lever 30 30 will increase throttle opening and the neutral release lever is pulled up and toward forward or 30 toward boat speed choke fast idle lever is in the lowest reverse to engage the desired gear position 57 6 OPERATION REMOTE CONTROL TYPE Cruising POWER TRIM TILT SWITCH LOWEST POSITION 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 58 N neutral F Forward MAXIMUM OPENING 2 Move t
18. system Lubrication system Trochoid pump pressure lubrication Description Code BAZS Type x ow Overall length 27 0 in 28 6 in 27 0 in Specified oil Engine API standard 685 mm 725 mm 685 mm Fuel Efficient SG SH SAE Overall width 14 6 in 370 mm 3W 30 Gear case API standard GL 4 5 Overall height 53 6 in 1 360 mm SAE 90 outboard motor gear oi X 57 5 in 1 460 mm 20 5 in 520 mm 24 5 in 622 mm 198 tb 203 Ib 90 kg 93 kg 92 kg 212 b Rated power 50 HP 37 3 kW Full throttle range 5 500 6 000 rpm Engine type 4 stroke OHC in line 3 cylinder Displacement 49 3 cu m B08 Spark plug gap 0 024 0 028 in 0 6 0 7 mm P Engine 2 5 US qt 2 4 lit Gear case 0 53 US qt 0 5 lit Transom height Transom angle 5 stages 11 5 15 59 19 52 23 5 27 89 106 14 WARRANTY SERVICE Warranty Service Information Servicing dealership personnel are trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager or General Manager can help Almost all problems are solved m this way If you are dissatisfied with the decision made by the dealership s management contact the Honda Marine Customer Relations Office You can write American Honda Motor C
19. then install the new propeller in the r verse sequence of removal Hand tighten the castle nut until the 4 mm cotter pin can be installed if necessary tighten the castle nut just enough to align the hole with the groove in ihe nut Use a new genuine Honda cotter pin and bend the cotter pin ends as shown 10 MAINTENANCE Submerged Motor A submerged motor must be serviced immediately after it is recovered from the water in order to minimize corrosion Immediately take the outboard motor to the closest authorized Honda Marine dealer or if you are far froma dealership proceed as follows 1 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 3 Disengage the emergency stop switch clip from the emergency stop switch 4 Remove the spark plugs EMERGENCY STARTER ROPE Remove the flywheel cover following the emergency starting procedure refer and remove the water from the cylinders by pulling the emergency starter rope several times If the motor was running when it submerged there may be mechani cal damage such as bent connecting rods if the engine binds when rotated with the emergency starter rope do not proceed or attempt to run the motor until it has been repaired the engine oil refer to page 87 7 Put a teaspoon of engine oil into each spark plug hole to lubricate
20. 13 3 CONTROLS TILLER HANDLE Throttle Grip Throttle Opening Indicator THROTTLE OPENING INDICATOR 7 SQ INCREASE THROTTLE GRIP Turn the grip clockwise or counter The label on the grip indicates throttle clockwise to adjust the engine speed opening Turning the grip in the direction shown by the arrow increases engine speed 14 Throttle Friction Knob THROTTLE FRICTION KNOB 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 Emergency Stop Switch Lanyard ENGINE STOP EMERGENCY STOP SWITCH CLIP ENGINE STOP SWITC EMERGENCY STOP SWITCH LANYARD Push the engine stop switch to stop the The emergency stop switch lanyard is Attach the emergency stop switch lan engine provided to stop the engine immedi yard securely to the operator when ately in the event the operator should operating the outboard motor fail 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 from the engine stop switch the engine will stop imme diately 15 3 CONTROLS TILLER HANDLE TYPE Oil Pressure Indicato
21. A damaged O ring seal can cause a fuel leak 5 STARTING THE ENGINE OUTLET END MOTOR PRIMER BULB Hold the primer bulb so that the outiet 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 39 5 STARTING THE ENGINE TILLER HANDLE TYPE ENGINE STOP SWITCH 2M K 2 EMERGENCY STOP EMERGENCY STOP SWITCH LANYARD SWITCH CLIP The water intakes must be lowered into the water Running the outboard motor out of the water will damage the water pump and overheat the engine l Engage the emergency stop switch clip located at one end of the emer gency stop switch lanyard with the engine stop switch Attach the other end of the emergency stop switch lanyard securely to the operator 40 SPARE EMERGENCY STOP SWITCH CLIP A spare emergency stop switch clip is provided near the engine stop switch 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 SHIFT
22. AREA NOT USE FOR LOMG TERM FUEL STORAGE MET B FLUSH THE SYSTEM THOROUGHLY WITH FRESH WATER DO HOT USE FUEL OIL HIXTURE FOLLOW BOTOR MANUFACTURERS RECOMMEMOAT SWALLOWED B ETARTIMQ INSTRUCTIONS ARE Oh TOF OF ENGINE WARNING FLAMMABLE DANGEROUS PRESSURIZED GAS GAS ME DO NOT PUNCTURE i OR INCINERATE DISKA INFLAMMABLE DANGEREUX BATIR BATEAN POUR REFATRE LE PLEIN ESSERE 0 AG OL I 2 COMPONENT IDENTIFICATION TILLER HANDLE TYPE THROTTLE GRIP FUEL LINE OIL FILLER CAP CONNECTOR TILLER OIL LEVEL HANDLE ENGINE COVER DIPSTICK GEAR SHIFT LEVER OIL PRESSURE INDICATOR LIGHT POWER TILT OID ATOR SWITCH LIGHT LHT type COOLING SYSTEM VM ao INDICATOR THROTTLE SWITCH oe FRICTION KNOB LOCK ENGINE OIL au ANGLE LEVER DRAIN PLUG AU 032 il ADJUSTING ACCESS COVER zum 2 ANTICAVITATION 4 MANUAL X PLATE m LH Sn RELIEF vive Bae chai LHT type WATER INTAKE EMERGENCY GEAR OIL TRIM TAB STOP SWITCH LEVEL PLUG ANODE METAL CLIP WASH PLUG SPARE EMERGENCY Flush plisg eee STOP SWITCH CLIP PROPELLER optional EMERGENCY GEAR OIL DRAIN PLUG PAN EDT 10 2 COMPONENT IDENTIFICATION REMOTE CONTROL TYPE ENGINE COVER FUEL LINE POWER TILT OIL FILLER CAP CONNECTOR CHOKE KNOB except LR type OIL LEVEL POWER TRIM TILT RELEASE LEVER DIPSTICK SWITCH
23. CTOR 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 SPRING RETAINER FUEL FILTER 3 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 F EL HOSE CLIPS Change Remove the fuel filter Before removing the fuel filter to prevent fuel leakage place fuel hose clamps on the fuel hases at each side of the fucl filter ARROW Fuel Flow Direction 2 Install the new fuel filter so the arrow on the fuel filter points toward the fuel pump Fuel flaw will be reduced if the fuel filter is installed backward 3 Connect the fuel hoses to the fuei filter securely with the hose clips Remove the fuel hose clamps used to close the fuel hoses 95 I0 MAINTENANCE 4 Securely connect the fuel hose Fuel Tank and Filter connecto the outboard motor refer to page 38 5 Prime the engine using the primer bulb refer 39 Check for fuel leaks Repair any fuel leaks if necessary Joss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter inspect the fuel tank Cleaning interval Clean the fuel tank and tank filter if Every 200 hours Refer to the ne
24. ERIOD 3 Perform at every indicated month EVERY EVERY or operating hour intervals EACH USE 100 HRS OR 400 HRS OR whichever comes first MONTHS ITEM Change 1 Gear case oil Check fevel and check for water contamination o l 0 Change _ Carburetor linkage Check O2 o2 Valve clearance Checkreadiust plugs Check clean Replace if necessary Propeller and cotter pin Check o Replace if necessary Lubrication Grease 10 MAINTENANCE REGULAR SER VICE PERIOD 3 Perform at every indicated month or operaling hour intervals whichever comes first FIRST EVERY EVERY EVERY EACH USE 20 HRS 100 HRS OR 200 HRS 400 HRS OR OR MONTH 6 MONTHS OR YEARLY 2 YEARS ITEM Fueltank and filter filter Clean Replace if necessary Fuel filter Thermostat Fuel line Check Replace if necessary Battery cable Check tightness Bolts and Nuts Check tightness Emission related items 1 Lubricate more frequently when used in salt water 2 These items should be serviced by an authorized Honda Marine dealer unless the owner has the proper toois and is mechanically proficient See the Honda Shop Manual 3 For professional commercial use log hours of operation to determine proper maintenance intervals 86 10 MAIN
25. GENCY STOP 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 lime to time to be sure that the switch is operating properly 74 Normal Engine Stop N THROTTLE GRIP 1 Turn the throttle grip to SLOW position and move the gearshift lev er to N neu ral ENGINE STOP SWITCH 2 Push the engine stop switch until the engine stops 7 STOPPING THE ENGINE TILLER HANDLE TYPE 75 7 STOPPING THE ENGINE REMOTE CONTROL TYPE Emergency Engine Stop EMERGENCY PSWITCH SE EMERGENCY STOP EMERGENCY STOP SWITCH CLIP Disengape 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 76 SWITCH LANYARD Normal Engine Stop neutral LEVER edd t M 1 Move the control lever to the N neutral position and turn the igni tion key to the OFF position IGNITION KEY 2 When the boat is not in use remove and store the ignition key 8 TRANSPORTING Trailering When trailering or transporting the boat with the motor attached 1t 15 recommended that the motor remain in the normal run position Tighten the
26. HOND A BFAOA 50A Owner s V MARINE Manual LL EL E LL LL EL E LL LL EI ELI LLL iain t ng 2 LL LL _ tt mili gt 4 LI LL LL LE LL E LL EL LLL EL LI LL Tt tt LI LLLLLLLLLLIJI _ LL LLL etd _ ETT TTT TT TT 11111 a HONDA MOTOR CO LTD 1999 NENNEN 2 eT TEE TTT TT ET TT TET TT WARNING engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold The information and specifications included in this publication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the night however to discontinue or change specifications or design at any time without notice and without incumng any obligation whatever No part of this publication may be reproduced without written permission INTRODUCTION Congratulations on your selection of a Honda outboard motor We are certain you will be pleased with your purchase of one of the finest outboard motors on the market We want to help you get the best results from y
27. Motor GAS ASSISTED TILT TYPE POWER TRIM TILT POWER TRIM TILT TYPE Trim Meter Power Tilt Switch Motor Manual Relief Valvc Lock Lever Trim Tab Adjustment MOTOR PROTECTION SYSTEM Engine Oil Pressure and Overheat E System Over Rev Limiter Power Trim Warming System Anodes Shallow Water Operation Engine Fuel Filter Fuel Tank and Filter eene Fuse Replacement 2 2 2 dis TILLER HANDLE TYPE erm 74 eo Ror 76 78 arc NEU ME NP 80 THE pon NE OF MAINTENANCE 80 MAINTENANCE SAFETY 4 80 EMISSION CONTROL SYSTEM INFORMATION 81 Tool Kit and Spare 188 84 MAINTENANCE SCHEDULE 83 ei tei te es 87 Gear Oil Spark Plugs Battery not included 92 Esse c 93 Submerged annee 99 101 2 TROUBLESHOOTI 103 105 107 n 108 111 1 OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION Honda 4 and BF50A outboard motors are designed for use with boats that have a suitable manufacturer s power recommendation and other
28. OIL PRESSURE INDICATOR STEERING CONTROL LIGHT PLATE LEVER OVERHEAT INDICATOR TILT TILT LEVER LIGHT LEVER UR type CHOKE FAST TRANSOM STERN IDLE LEVER ANGLE 2 COOLING BRACKET i IGNITION ADJUSTING INDICATOR SWITCH lt a ENGINE OIL SPARE EMERGENCY MANUAL DRAIN PLUG STOP SWITCH CLIP RELIEF VALVE ACCESS COVER LRt BUZZER except TRIM TAR inside of the box Sy GEAR OIL GEAR OIL EXHAUST PORT EMERGENCY STOP DRAIN PLUG SWITCH LANYARD PROPELLER optional WATER INTAKE EMERGENCY WASH PLUG EMERGENCY STOP ENGINE STOP Flush ptug SWITCH CLIP SWITCH 2 COMPONENT IDENTIFICATION a POWER TRIM TILT TYPES VENT KNOB FUEL GAUGE FUEL TANK FUEL CAP TACHOMETER FUEL HOSE FUEL HOSE CONNECTOR FEMALE TRIM METER PRIMER BULB 12 3 CONTROLS TILLER HANDLE TYPE Engine Start Button ENGINE 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 SHIFT 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 CHOKE KNOB When the engine is cold pull the Choke knob rich fuel mixture is provided to the engine by pulling the choke knob
29. OMMON Fuel Cap Gauge Vent Knob VENT KNOB GAUGE FUEL FILLER CAP 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 disconnect the fuel hose connector from the outboard motor refer to page 38 Gasoline is extremely flammable and gaso lina 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 rey 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 rpm to stabilize then slowly increase the throttle opening On the power trim tilt type motors lower the tr
30. P to raise bow Press DN to lower bow CONTROL LEVER On the tiller handle type the power trim tilt switch is the optional part The power trim tilt switch is available on your authorized Honda Marine dealer NOTICE Excessive trim tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over revving Excessive trim tilt angle can also damage the water pump and overheat the engine To trim motor up slightly press the UP portion momentarily To trim motor down slightly press the DN portion momentarily 6 OPERATION POWER TRIM TILT TYPE TILT ANGLE 0 TRIM ANGLE Decrease the trim angle on high speed turns to reduce the possibility of propel ler ventilation 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 70 MOTOR TRIMMED MOTOR TRIMMED TOO LOW TOO HIGH MOTOR TRIMMED ROUGH CORRECTLY WAVES When cruising Into a high wind trim the motor down slightly to level the bow and improve boat stability B With a taal wind trim the motor up slightly to raise the bow and improve boat stability C Through rough waves do not trim the motor too low or too high to avoid an unstable steering condition 63 6 OPERATION POWER TRIM TILT TYPE Tri
31. TENANCE Engine Oil Engine oil is a major factor affecting engine performance and service life Oil check interval Fach use Oil change interval After the first 20 hours then every 100 hou Refer to the maintenance schedula page 85 OIL CAPACITY 2 1 US qt 2 0 lit When oil filter is not replaced 2 5 US qt 2 4 Iit When oil filter is replaced Recommended oil BF40A 50A SAESW 30 engine oil API Service classification Fuel Efficient SG SH es OIL FILLER Ep CAP GE y 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 87 10 MAINTENANCE 0 RAIN PLUG COVER SCREW 2 Loosen the drain plug cover screw using a flat blade screwdriver and remove the drain plug cover 88 DRAIN PLUG COVER 3 Place the drain plug cover as shown to use it as an oil drain guide Place a suitable container under the guide SEALING WASHER 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 limit mark on the oll level dipstick with the recom mended oil NOTE To avoid incorrect gauging of the engi
32. activated 1 Immediately decrease the trim angle by pressing the DN portion of the power trim tilt switch 2 Immediately reduce the throttle opening to SLOW and operate the engine at low speed Anodes e ANODE trim tab ANODEistern bracket The anodes a sacrificial mat nal which helps to protect the outboard motor from corrosion 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 71 6 OPERATION Shallow Water Operation NOTICE 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 dantage the water pump and overheat the engine When operating in shallow water tilt the motor up to prevent the propeller and gear case trom hitting the bottom refer tol pages 59 and 62 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 72 If the motor trim angle is more than 20 and the control lever is moved more t
33. an 5 minutes at time For boats that plane easily bring the boat up on plane then reduce the throttle opening to the specified break in settings called out above 53 6 OPERATION TILLER HANDLE TYPE Gear Shifting N neutral THROTTLE GRIP 7 F forward SLOW 20 A FAST POINTER c INDICATOR Gearshift lever has 3 positions The throttle mechanism is designed to 2 On the Gas assisted type put the tilt FORWARD NEUTRAL and limit the throttle grip travel when lever in the LOCK position to prevent REVERSE operating in the REVERSE or NEU the outboard motor from tilting up An indicator at the base of hae E TRAL positions The throttle grip can when operating in reverse refer to gearshift lever aligns with the letters F only be tumed to the FAST position page 25 N and R on the motor pan y p when operating in forward gear 1 Align the pointer on the tiller han 4 LEVER TONE SEE dle with the SLOW position on the idi throttle grip to decrease engine speed 54 6 OPERATION TILLER HANDLE TYPE Steering Cruising RIGHT TURN LEFT TURN H Move the tiller Move the tiller handle to the left handle to the right POSITION The tiller handle is moved in the oppo On the Power trim tilt type press the site direction in which you want the boat DN portion of the power trim tilt switch to turn optional part and tilt the motor to the lowest position The
34. 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 Gasohal MTBE Methyl Tertiary Butyl Ether 15 by volume You may use gasoline containing up to 15 MTBE by volume 34 METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up ta 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 may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms an other service station or switch to another brand of gaso line Fuel svstem 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 COTTER PIN 4 stainless steel PROPELLER The propeller Propeller Cotter Pin blades are thin and sharp Careless handling of the Che
35. cessary It may be necessary to drain maintenance schedule nage 86 the fuel tank completely and refill with fresh gasoline Inspect the condition of the fue cap gasket fuel hose and the O ring seals in the fuel hose connectors Replace the fuel cap pasket hose or fuel con nectors if they are cracked damaged or leak fuel Be sure the fuel hose is not kinked 96 Fuel Tank Cleaning 1 Disconnect the fuel hose from the fuel tank Gasoline is extremely flammable and gaso line vapor can explode causing serious injury or death Do not smoke or allow flames or sparks m 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 smail quantity of fresh gasoline and clean the tank thoroughly Drain and dispose of the gasoline properly 10 MAINTENANCE FUEL TANK HOSE CONNECTOR lt O RING d gau FUEL TANK FILTER Fuel Tank Filter Cleaning Replacement 1 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 stall the fuel tank filter and fuel tank hose connector securely Fuse Replacement A Bus BLOWN FUSE If thc fuse is blown running the engine will not charge the battery and the electric starter and po
36. ck the propeller blades for damage Check the cotter pin for damage and propeller can result in injury wear or deformation and replace if correct installation If the cotter pin when checking the propeller necessary Never operate the outboard needs replacement use only a new Remove the clip of the motor with a damaged propeller genuine Honda stainless steel cotter pin emergency stop switch to prevent accidental engine Carrying a spare propeller propeller starting nuts and Cotter pins are common Wear heavy gloves when practice If the propeller is damaged and handling the propeller no spare propeller is available consult an authorized Honda Marine dealer Refer to for propeller change information 35 4 PRE OPERATION CHECKS Steering Friction Adjustment common TO DECREASE FRICTION STEERING FRICTION ADJUSTER tt Th TO INCREASE FRICTION Operate the steering wheel or tiller handie right and left and check for the amount of drag Adjust the steering friction adjuster so that a slight amount of drag is felt The X steering should move smoothly and freely 36 Remote Control Friction Adjustment TO INCREASE X FRICTION b md TO DECREAS FRICTION ADJUSTER Operate the remote control lever into forward and reverse gears and check for the amount of drag felt Adjust the remote control friction adiuster so that a slight amount of drag is
37. d off after running at full throttle the engine temperature may rise above normal 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 obstructions If there are no obstructions at the water intakes return to the closest boat landing and contact your closest authorized Honda Marine dealer 69 6 OPERATION MOTOR PROTECTION SYSTEM Over Rev Limiter Power Trim Warning System 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 1s activated 1 Reduce the throttle opening immedi ately and check the trim angle 20 If the motor trim angle is more than 2 f the trim angle is correct but the 20 and the control lever is moved over rev limiter stays activated stop more than 40 forward rearward from the engine and check the condition of the N neutral position an intermit the outboard motor and check the tent buzzer wiil sound and beep at propeller for damage Correct or second intervals Service as necessary 70 6 OPERATION MOTOR PROTECTION SYSTEM When the power trim warning system is
38. e oil leakage Vertical transport or storage Attach the stem bracket to stand 102 12 TROUBLESHOOTING 1 Engine does not start Fuel Fuel is not fed There is no gasoline No sparks Spark plug Contamination to carburetor in fuel tank across spark is Taulty Incorrect gap Vent knob is not open or plug gap Broken spark plug vent clogged Fuel filter is clogged Pulser coil is faulty Fuel line is kinked Current leaks from Fuel line is connected high tension cord improperly C D L unit is faulty Fuel pump is faulty Exciter coil is faulty Primer bulb is faulty Ignition coil is faulty Check valve in connector Wire harness is faulty is faulty Current leaks from engine stop e Fuel 15 fed to Excessive amount switch cord carburetor of fuel overflow Stop switch does not retum Carburetor vent is satisfactorily clogged Spark plug is improperly installed Electrical Emergency stap switch is improperly Sparks across Insufficient Spark plug gap is small installed spark plug gap sparks Weak starter motor Shift lever is not in N position rotation Normal Recheck the fuel system sparks 103 12 TROUBLESHOOTING 2 2 Engine starts but immediately stops Engine some times stops while cruising Fuel No gasoline in fuel tank There is gasoline in fuel tank 104 Water is mixed with gasoline Vent knob is not open or vent is clogged Fuel filter is c
39. en the boat amount of effort is required to turn the moving the tilt lever to the LOCK is moored for a long time steering wheel or tiller handle right or position locks the motor in the desired Tilt the motor up as far as it will go then left adjust the trim tab so that an equal position Use the tilt lever to temporarily move the tilt lock lever into the lock amount of effort is required tilt the motor when the boat is operating position and gently lower the motor 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 25 3 CONTROLS COMMON 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 1s required If adjustment is necessary loosen the tightening bolt and tum the irim tab nght or left Make smali adjustments at a time and retest Incorrect trim tab adjustment can cause adverse steering The trim tab also functions as an anode 26 Anode Metal S E ANODE trim tah ANODE stern bracket The anodes are made from a sacrificial matertal which helps to protect the outboard motor from corrosion NOTICE Painting or coating the anodes will lead to rust and corrosion damage to the outboard motor 3
40. eplace the trode spark plugs if there is apparent wear or if the insulators are 1 Allow the engine to cool The spark cracked or chipped Clean the spark plugs will be hot if the engine has plugs with a wire brush if they are been running to be reused 2 Remove the engine cover 91 10 MAINTENANCE 7 Thread the plugs by hand 10 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 1 2 turn after the spark plugs seat to com press the washers If reinstalling used spark plugs tighten 1 8 1 4 turn after the spark plugs seat to compress the washers 92 a eli enc Battery not included The spark plugs must be Minimum requirements securely tightened A loose spark I2V TOAH marine cranking battery plug can become very hot and may cause engine damage Overtightening the spark plugs can damage the threads 10 MAINTENANCE To protect the battery from mechani Lubrication cal damage and to prevent the bat Lubrication interval After the first 20 hours then every 100 hours tery from falling or tipping over the Refer to the maintenance schedule page 85 battery must be Apply marine anticorrosion grease to the following parts Installed in the correct size corro THROTTLE REEL sion resistant battery box Properly secured in the boat SWIVEL CASE e Secured in a location free fro
41. er REM 24 Throttle Friction Knob 4 14 CUT REM id Opening Indicator 14 CENE 25 Tilt Lock Lever CONTROLS essere mener rrr entra treten tente 25 OPERATION 66 Tilting motor GAS ASSISTED TILT 2 222222 2 42 4421 59 POWER TYPE saanen 62 DRAKE 37 Tool and Spare Parts i e ehem nane nnnm nennen mann nnns 84 Transom Angle Adjusting Rod sassa 28 TRANSPORTING oo eese eren rne nennen anna crassi tana cas 77 Trim Meter Controls essere nera netten e EPA HE EE MA EAE EPA EE 23 2222 22 2 2 22 2 2 2 bd Frim Tab MERE 25 16 INDEX Trim Tab Adjustment 2 2 22 212 221 2211 0 2 1 1 2 0 0 nns 67 Starting Problems 52 WARRANTY SERVICE 1 1 2 107 Water Makes RR 27 113 HON DA HONDA MOTOR CO LTD TOKYO JAPAN LLL EL EL EL LE LE LE LE LE LE LE HL LUE ET E LE IL LL LLLELL 31zw4603 200200208 _ E 00X31 ZW4 6030 LL bL g Ppp PRINTED IN U S A LILLLLLLLLLLLLLL IL C IL
42. eter Fpm x 1000 Tie TACIIOMETER The tachometer shows the approximate engine speed in revolutions per minute Refer to the tachometer when using the power trim tilt switch to achieve proper boat and motor performance 24 Manual Relief Valve 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 ult the outboard motor manually tura the manual valve under the left stern bracket no more than 1 or 2 turns counterclock wise using a screw driver After tilting the motor tum the manual relief valve clockwise securely The manual relief valve must be tight ened securely before operating the motor or thc motor could tilt up when operat ing in reverse LEFT STERN BRACKET ES MANUAL POWER To release MANUAL RELIEF VALVE Do not turn this screw If this screw is tarned 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 GAS ASSISTED TILT TYPE 3 CONTROLS COMMON Tilt Lever GAS ASSISTED Tilt Lock Lever Trim Tab TIGHTENING ipm BOLT EY 1 ae 1 TRIM TAB PROPELLER Moving the trit lever to the FREE Use the tilt lock lever to hold the motor When making a turn if an unequal position allows the motor to be tilted and in the highest tilt position wh
43. felt The remote control lever should move smoothly and freely 4 PRE OPERATION CHECKS Other Checks 3 Toot kit The following materials should be kept 5 4 with the boat 12 mm WRENCH ay ree c 1 Owner s Manual oo EMERGENCY 2 Tool Kit STARTER ROFE 1 WRENCH 3 Spare engine oil spark plugs FLAT SCREWDRIVER Md propeller propeller cotter pins and nut HILLIPS SCREWDRIVER SCREWDRIVER 4 Required information regarding boating laws and regulations screwpaiver 22 99 LE x WRENCH Check the following items Replace anodes when they are visibly 1 The fuel hose for kinking collapsing reduced in size or crumble easily or loose connections 2 The stern bracket for damage and NOTICE Painting or coating the mounting bolts for proper torque anodes will lead to rust and corrosion 3 The tool kit contents Compare your damage to the outboard motor tool kit contents against the tool kit illustration above Replace any missing items 4 The anodes for damage looseness or EXCESSIVE corrosion The anodes help to protect the outboard motor from corrosion any time they are exposed directly to the water 37 5 STARTING THE ENGINE Fuel Tank and Vent Knob VENT KNOB The fuel tank must be properly secured in the boat This will protect the fuel tank from damage caused by the fuel tank shifting The fuel tank must be m a well venti lated area to reduce the chance of a ga
44. ft up on the engine cover grip and swing the tilt lock lever to the FREE position 5 Lower the engine gently Move the tilt lever to the LOCK position 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 td page 60 then pull the engine cover grip and tilt the motor all the way up 2 Move the tilt lock lever to the LOCK position and lower the outboard motor slowly 61 6 OPERATION POWER TRIM TILT TYPE type outboard refer to page 23 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 com pensate for boat load or weight distribu tion water conditions propeller or engine condition Thc motor tnm angle can be adjusted while accelerating or cruising 10 obtain the maximum boat speed optimum boat stability and fuel economy Under normal conditions the boat will achieve optimum boat per formance when the motor is running at maximum rpm and the ventilation plate is level with the water Press either the UP or DN portion of the power trim ult 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 15 released 62 POWER TRIM TILT SWITCH remote control type Press U
45. han 40 forward rearward from the N neutral position the power trim warning system will be activated refer to page 70 Power trim tils 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 modifi cations to the carburetors if you always operate your outboard at altitudes above 5 000 feet 1 500 meters have an authonzed Honda Marine dealer perform this carburetor modification Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made 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 below 5 000 feet 1 500 meters with modified carburetors may cause the engine to overheat and result in sericus engine damage For use at low altitudes have an authorized Honda Marine dealer return the carburetors to original factory specifica tions 73 7 STOPPING THE ENGINE TELLER HANDLE TYPE Emergency Engine Stop ENGINE STOP SWITCH EMERGENCY STOP SWITCH LANYARD PULL EMER
46. he 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 N ENGINE STOP SWITCH 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 ENGINE COVER GRIP TILT LEVER To tilt the motor up move the tilt lever to the FREE position then pull the engine cover grip and raise the motor Do not push down on the tiller handle 59 6 OPERATION GAS ASSISTED TILT TYPE oU eee 1 _ 3 With the outboard motor tilted up to 4 To lower the motor back down the desired position move the tilt move the tilt lever to the FREE lever to the LOCK position to lock position while holding the engine the motor cover grip then lower the motor gently Move the tilt lever to LOCK position The tilt lever be in the LOCK position before operating the motor or the motor could tilt up when operating in reverse 60 6 OPERATION GAS ASSISTED TILT TYPE TILT LOCK 3 Move the tilt lever to the LOCK LEVER position flock position 4 To lower the motor move the tilt lever to the FRHE position Li
47. im angle on high speed turns to re duce the possibility of propeller ventila tion 29 4 PRE OPERATION CHECKS Engine Cover Removal Installation FRONT KEAR Co 4 V ENGINE COVER N MUN LATCHES 4 remove release the front and rear engine cover latches and remove the engine cover To install position the engine cover over the engine and hook and lock the front and rear latches 30 4 PRE OPERATION CHECKS Engine Oil Engine oil is a major factor affecting engine performance and service life NOTICE Running the engine with insufficient otl can cause sertous engine damage Recommended oil Use high detergent premium quality 4 stroke engine oil certified to meet or exceed 17 5 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 arca SAE 5W 30 is recommended for gen eral all temperature use BF40A 50A Service Grade Use a Fuel Efficient SG SH oil NOTE This oil is usually identified by words such as Energy Conserving 9 T IL Gas Saving Fuel Saving etc TEMP 9 99 3 20 0 20 30 40 C Inspection 1 Position the outboard motor verti cally and remove the engine cover 2 Remove the oil level dip
48. ion in which you can be seriously hurt or killed Always follow the inspection and maintenance recommen dations and schedules in this owner s manual To help you properly care for your outboard motor the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic 80 hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda techni cian or other qualified mechanic The maintenance schedule appites to normal operating conditions If you operate your outboard motor under unusual conditions consult your servic ing dealer for recommendations applica ble to your individual needs and use Maintenance replacement or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual using parts that are certified to EPA standards MAINTENANCE SAFETY Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing tnainte nance Only you can decide whether or not you should perform a given task Failure to properly follow maintenance instruc tions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this own er s manual 10 MAINTENANCE Safety
49. l find important safety information a variety of forms including e Safety Labels on the outboard motor Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal word s mean A DA R You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY A WARNING you don t follow instructions ris CAUTION You CAN be HURT if you don t follow Instructions Safety Headings such as IMPORTANT SAFETY INFORMATION Safety Section such as OUTBOARD MOTOR SAFETY Instructions how to use this outboard motor correctly and safely This entire book is filled with important safety information piease read it carefully It may be necessary to refer to this chart for reference purposes when reading this manual TYPES OF HONDA BF40A 50A OUTBOARD MOTORS Type Shaft Length Tiller Remote Gas Assisted Power Trim Tachometer Trimmeter et e Tse ane TYPE CODE example L R T T Power Trim Tilt R Remote Control H Tiller Handle X Extra Long Shaft L Long Shaft IDENTIFICATION NUMBERS STARTER MOTOR hh RIGHT STERN BRACKET foi EL fon PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER Record the Product Identification The Product Identification Number is Number P LIN and the Engine Serial stamped
50. logged Air screw is open too wide Idling speed is too slow Carburetor vent 15 clogged Fuel pump is faulty Air in fuel pump Air enters through fuel line connector Air enters through primer bulb Enpine overheats Water intake screens are 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 Normal sparking 13 SPECIFICATIONS Starter system Trochoid pump pressure lubrication Specified oil Engine API standard Fuel Efficient G SH SAE 5W 30 Gear case API standard GL 4 5 SAE 90 outboard motor gear cil Oil capacity Engine 2 5 US qt 2 4 lit Gear case 0 53 US gt 0 5 lit D C output 12 V 10 A Cooling syste Exhaust system MODEL BF40A BAYS Overall length 28 61 270 28 6in 27 0 in 725 mm 685 mm 725 mm 685 mm Sone Spark plugs DRIEA NGK X22ESR U DENSO Fuel pump Diaphragm type Weight 201 1b 1981b 205 203 1b 91 kg 90 kg 93 kg 92 kg 212 Ib 96 kg Fuel Automotive gasoline 86 pump octane Tank capacity 6 6 US gal 25 lit Gear change Forward Neutral Reverse dog type Steering angle 37 5 right and left Transom angle 5 stapes 11 3 15 5 19 54 23 57 27 3 105 13 SPECIFICATIONS MODEL BFSOA Starter system Electric starter Ignition
51. m 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 LOW DUE TO BOW TOO HIGH DUE TO 1 LOAD IN THE FRONT 1 LOAD IN THE REAR 2 MOTOR TRIMMED TOO LOW 2 MOTOR TRIMMED TOO HIGH With the motor trimmed low the trim With the motor trimmed high the trim meter will read as shown To raise the meter will read as shown To lower the bow increase the motor trim angle by bow decrease the motor trim angle by pressing the UP portion of the power pressing the DN portion of the power trim tilt switch trim tilt switch 64 6 OPERATION POWER TRIM TILT TYPE Power Tilt Switch Motor Pan Manual Relief Valve LEFT STERN BRACKET eM 2 it ae MANUAL RELIEF VALVE gt MANUAL POWER MANUAL POWER TILT SWITCH 9 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 Do not turn this screw Hf 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 s
52. m di rect sunlight and water spray e Secured away from the fuel tank to avoid potential sparks near the fuel tank Install the battery in the battery box 2 Connect the positive 4 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 93 10 MAINTENANCE Engine Fuel Filter FUEL PUMP CARBURETOR FUEL FILTER The engine fuel filter is located under ihe 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 mainte nance schedule page 86 Change interval Every 400 hours Refer to the mainte nance schedule page 86 94 Gasoline is extremely flammable and gaso line vapor cain explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN Always work in a well ventilated area Make sure that any fuel drained from the outboard motor is stored in an approved gasoline container Be careful not to spill any fuel when replacing the filter Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine CONNE
53. 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 CHOKE FAST IBLE LEVER Do not turn the ignition key to the start position while the engine is running This can damage the starter motor and flywheel 3 After starting the engine return the lever slowly to the position where the engine does not stall and hold the lever in this position The control lever will not move unless the choke fast idle lever is returned to the lowest positon 45 5 STARTING THE ENGINE REMOTE CONTROL TYPE COOLING SYSTEM INDICATOR 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 Lf the problem continues contact your closest authorized Honda Marine dealer NOTICE Running the outboard motor with an obstruc tion in the cooling system can damage the water pump and overheat the engine 46 PRESSURE INDICATOR LIGHT NORMAL GREEN LIGHT ON ABNORMAL GREEN LIGHT BLINKING OR OFF With the engine running
54. ne 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 ina 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 change interval After the first 20 hours then every 100 hours Refer to the maintenance schedule page 85 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 89 10 MAINTENANCE DRAIN PLUG LEVEL PLUG Gear Oil Level Check l 2 Position the outboard motor verti cally Remove the level plug and see if oil flows out If no oil flaws 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 ihe 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 90 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
55. ning until the TILLER HANDLE malfunction is corrected When the malfunction is corrected the engine speed will increase gradually RED S ee INDICATOR LIGHTS Qe tunt E REMOTE CONTROL TYPE Symptom pressure OFF ON Continuous overheat 68 6 OPERATION MOTOR PROTECTION SYSTEM When the oil pressure warning sys tems 18 activated 1 Stop the engine immediately and check the engine oil level refer to page 31 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 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 i 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 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 turne
56. o Inc Marine Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you write or call please give us this information Model and serial numbers see page Name of the dealer who sold the outboard motor you Mame and address of the dealer who services your outboard motor Date of purchase e Your name address and telephone number A detailed description of the problem 107 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
57. 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 effort required Lepr TRIM TAB is 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 NOTICE Painting or coating the anode will lead to rust and corrosion damage to the outboard motor 67 6 OPERATION MOTOR PROTECTION SYSTEM T GREEN BUZZER AS Es Q T OVERHEA A _ Engine Oil Pressure and Overheat Warning System If the engine oil pressure drops and or the engine overheats either or both warning systems could be activated When activated the engine speed will decrease gradually and the preen 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 enpine speed can not be increased with a larger throttle ope
58. oke fast idle lever The choke fast idle lever wiil stay up in the fast idle position 50 5 STARTING THE ENGINE EMERGENCY STARTING FLYWHEEL Dim po 4 KNOT ARN a 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 on 10 1f 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 stali Exposed moving parts can cause injury Use extreme care when instailing the engine cover Do not oper ate the outboard motor without the engine cover 12 Leave 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 SI 3 STARTING THE ENGINE Troubleshooting Starting Problems SYMPTOM Starter motor doesn t ium Starter motor turns over but engine wil not start ty POSSIBLE CAUSE 1 Shift lever not in ne
59. on teet nemen ne me ee Pa ERE E ER HN 93 rie ennemis 80 EMISSION CONTROL SYSTEM INFORMATION 8I MAINTENANCE SAFETY nnn 80 SCHEDULE 1 ae d HR n 82 THE IMPORTANCE OF MAINTENANCE 80 Choke 20 Relief Valve CONTROLS ceseesensetedaatesaeeeedteseedernaenees 24 OPERATION 5 eere nennen nnm nn nnnm nnn s 65 MOTOR PROTECTION SYSTEM 1 2 68 111 16 INDEX Neutral Release Lever eese cessere ee nennen rens 18 Pressure Indicator reet 16 Oil Pressure Indicator 119 zl Other CHECKS 3 OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION 7 SAFETY LABEL LOCATIONS eese ens 9 Over Rev Limiler 70 Overheat Indicator Light 222 2 4 1 200 1 Overheat Indicator Light Buzzer eese nne il Oxygenated Fuels 2 34 Power Tilt Switch Motor Pan 5 23 OPERATION
60. op switch lanyard with the emergency engine stop switch ttach the other end of the emer gency stop switch lanyard securely to the operator 44 If the operator doas not attach the emergency stop switch lanyard and is thrown from his seat or out of the boat the out of cantrol 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 1s engaged with the emergency engine stop switch SPARE EMERGENCY STOP SWITCH CLIP 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 may be necessary to raise the choke fast tdle 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
61. our new outboard motor and to operate it safely This manual contains the information on how to do that please read it carefully As you read this manual you will find information preceded by a symbol That information is intended to help you avoid damage to your outboard moter other property or the environ ment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy is a separate document that should have been given to you by your dealer When your outboard moter needs scheduled maintenance keep in mind that your Honda marine dealer is specially trained in servicing Honda outboard motors Your Honda marine dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns 1999 Honda Motor Co Ltd All Right Reserved INTRODUCTION A FEW WORDS ABOUT SAFETY Y our safety and the safety of others are very important And using this outboard motor safely 1s an important responsibil ity help you make informed decisions about safety we have provided operat ing procedures and other information on labels and in this manual This informa tion alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about ali the hazards associated with operating or maintaining an outboard motor You must use your own good judgment You wil
62. r Light Overheat Indicator Light Mcd H CLIP 5 2 GREEN d D D LM a DAE OIL PRESSURE INDICATOR LIGHT OVERHEAT INDICATOR LIGHT A Spare emergency stop switch clip is The green oil pressure indicator light When the engine cooling system is provided near the engine stop switch is normally ON when the outboard faulty the red overheat indicator light motor is running turns ON and the engine speed When the engine oil level is low or the decreases gradually engine lubrication system is faulty the green oil pressure indicator light turns OFF and the engine speed decreases gradually 16 3 CONTROLS REMOTE CONTROL TYPE Remote Control Lever N NEUTRAL FORWARD 3 30 REVERSE THROTTLE OPENING Soe NEUTRAL RELEASE LEVER REMOTE CONTROL LEVER The remote control lever controls gear selection and throttle opening posi tions nad F forward R reverse i It is necessary to pull up the neutra Moving the lever to the F position Moving the lever to the K position release lever to operate the remote approximately 30 from the N approximately 30 from the N control lever position will engage the forward position will engage the reverse gear Moving the lever beyond gear Moving the lever beyond the R the F position will increase the position will increase the throttle throttle opening and the boat for opening and the boat reverse speed ward speed N neutral The transmission gea
63. r 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 NOTICE Running 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 PRESSURE INDICATOR LIGHT 9 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 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 tums ON Stop the engine if the oil pressure indicator light does not turn ON heck the engine oil level see page 31 If the oil level is normal and the oil pressure indicator light does not tum ON contact your closest author ized Honda Marine dealer 43 5 STARTING THE ENGINE REMOTE CONTROL EMERGENCY EMERGENCY STOP EMERGENCY STOP SWITCH CLIP SWITCH LANYARD MOTICE The water intakes must be lowered into the water 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 st
64. rd or away from the con normally stop the engine trols Attach the emergency stop switch lan The emergency stop switch clip must yard securely to the operator when be engaged with the emergency engine operating the outboard motor 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 19 3 CONTROLS REMOTE CONTROL TYPE Choke Fast Idle Lever N neutral CHOKE MAXIMUM FAST IDLE The choke fast idle lever provides two Lift and hold the choke fast idle lever functions up fully this vill provide a rich fuel 1 Electric choke solenoid activation mixture for easy engine start up 2 Engine fast idle Gradually lower the choke fast idle lever to the lowest positton to disengage The choke fast idle lever will not the choke and lower the idie speed 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 20 Manual Choke Knob A cas A manual choke knob is provided 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 CHOKE KNOB 3 CONTROLS REMOTE CONTROL TYPE Oil Pressure Indicator Light Buzzer Overheat Indicator Light Buzzer
65. riginal parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emis sion control system manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuiider of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule on page 85 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation will require more frequent service 83 10 MAINTENANCE Tool Kit and Spare Parts TOOL KIT The following tools and spare parts are supplied with the outboard motor for maintenance adjustment and emergency repairs 10 x 12 mm WRENCH EMERGENCY o gt STARTER ROPE 8 mm WRENCH gt DRIVER FLAT SCREW PLIERS en PHILLIPS SCREWDRIVER 20 SCREWDRIVER HANDLE CHECK SCREWDRIVER zp gs umm aA 18 x 19 mm SOCKET WRENCH 84 w TOOL BAG 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 P
66. rs are disen gaged 17 3 CONTROLS REMOTE CONTROL TYPE Neutral Release Lever NEUTRAL RELEASE LEVER The neuiral 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 18 Ignition Switch ON START SWITCH The remote controi 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 IGNITION ON To run the engine after starting the battery will discharge if the key is left in this position 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 1s not run nine 3 CONTROLS REMOTE CONTROL TYPE Emergency Stop Switch Lanyard EMERGENCY Cx MS AS 2 ee AT AQ ed T D 12 EMERGENCY STOP EMERGENCY STOP SPARE EMERGENCY SWITCH CLIP SWITCH LANYARD STOP SWITCH CLIP The emergency stop switch lanyard is The emergency engine stop switch A spare emergency stop switch clip is provided to stop the engine immedi should not he used to normally stop provided on the remote control box ately in the event the operator should the engine Use the ignition switch to fall overboa
67. s contains poisonous carbon gasoline vapor can explode Refuel monoxide Avoid inhalation of exhaust outdoors in a well ventilated area Never run the engine in a closed with the engine stopped Never garage or confined area smoke near gasoline and keep other flames and sparks away Remove any portable fuel tank from the boat for refueling Keep the portable fucl tank away from the battery or other potential spark SOUTCES Refuel carefully to avoid spilling fuel Avoid overfilling the fuel tank refueling tighten the filler cap securely If any fuel is spilled make sure the area is dry before starting the engine 1 OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS MEM wur GASOLINE Gi These labels are in the locations shown imr They wam you of potential hazards that could seriously injure you Read these I oret ENGINE GOMER REMOVER No labels carefully BE FHE ANTIVEMTILATION PLATE BELOW THE DM MOT SHIFT TO REVERBE SUDDENLY AT HIGH SFCEL EXTREMELY FLAMMABLE SPO FOR USE MOTOR FUEL UM Y HAY CONTALH LEAD ANTI DANGER OF FATAL IF SWALLOWED KEEP OUT OF REACH OF DO MOT IMALE VOHT IHA CALL PHYSICIAN LARD ATELY CAUTION KEEP TOTALLY DLOSED WHEN NT IN LEE KEEP AMA FROH HEAT SPARK ANO OPEN FLAME LAD oyun E CHECK OIL LEVEL BEFORE STARTING ABOVE DETA WELL VENTILATED
68. soline vapor explosion Avoid direct 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 38 1 Open the fuel rank vent by turn ing the vent 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 fue rank to displace the fuel as the fuel ievel goes down 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 Replace the fuel hose or fuel hose connectors 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 FUEL HOSE CONNECTOR OUTBOARD END 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 If the outboard end fuel hose connector is forcibly installed in the reversed direction the fuel hose connector O ring seal can be dam aged
69. steering friction adjuster se curely to stop the motor s side to side movement STEERING FRICTION ADJUSTER H 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 of re move the motor from the boat ose the fuel cap vent knob refer to Disconnect the fuel coupling from the outboard motor refer 38 Horizontal Transport CASE PROTECTORS Before removing the motor from the boat drain the carburetors Follow the carburetor drain procedure on page 101 Always rest the motor on the case protcetors and be sure to protect it fram impact and damage 77 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 Plush Kit optional part 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 pear case 73 FLUSH KIT COUPLER Keep children and pets away frorn 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
70. stick 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 limit mark remove the oil filler cap and fill to the upper level mark with the recommended oil Do not overfill Excessive oil can damage the engine OIL FILLER CAP UPPER LIMIT 2 L LOWER BH LIMIT MARK 4 Reinstall the oil filler 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 puse 87 for oil capacity replacement interval and procedure 31 4 PRE OPERATION CHECKS Fuel Level FUEL GAUGE Check the fuel gauge and refill the tank to the SAFE FILL leve mark if necessary Fuel tank capacity 6 6 US gal 25 lit 32 ee Gasoline is extremely flammable and gaso line vapor explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN VENT KNOB f 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 securel
71. the inside of the cylinders Then rotate the engine several times us ing the emergency starter rope Reinstall the spark plugs NOTICE Running the outboard motor without sufficient cooling water wil damage the water pump and overheat the engine 99 10 MAINTENANCE E Engage the emergency stop 9 Take the outhoard motor to your Switch clip with the emergency closest authorized Honda Marine stop switch and attempt to start dealer for inspection and service the engime be sure the water as soon as possible level is at least 7 inches above the anti ventilation plate Ifthe engine fails to start re move the spark plugs clean and dry the electrodes then rc install the spark plugs and at lempt to start the engine again e Ifthe engine starts and no me chanical damage is evident continue to run the engine for a 1 2 hour or longer was water in the engine crankcase or the used engine oil showed signs of water contamina tion then a second engine oil change should be performed after running the engine for a 1 2 hour 7100 11 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 Be careful not to spill gasoline Spilled gasoline or gasoline vapor may ignite If any gasoline is spilled
72. uses result in injury to the operator or damage to the outboard motor and other property Most accidents can be prevented if you follow all instructions in this manual and on the outboard motor The most common hazards are discussed below along with the best way to protect yourself and others Operator Responsibility tis the operator s responsibility to provide the necessary safeguards to protect people and property Know how to stop the engine quickly in case of emergency Understand the use of all controls Stop the engine immediately if anyone falls overboard and do not run the engme while the boat is near anyone in the water Always stop the engine if you must leave the controls for any reason Attach the emergency stop switch lanyard securely to the operator e Always wear a PFD Personal Flotation Device while on the boat Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors Be sure that anyone who operates the outboard motor receives proper instruction Be sure the outboard motor is properly mounted on the boat Do not remove the engine cover while the engine is running not attempt to modify the outboard motor Do not remove any labels covers or safety devices they are installed for vour safety 1 OUTBOARD MOTOR SAFETY Refuel With Care Carbon Monoxide Hazard Gasoline is extremely flammable and Exhaust ga
73. utral position 2 Blown fuse 3 Weak battery 1 Emergency stop switch clip is not engaged 2 Qut of fuel 3 Vent knob not open 4 Primer bulb has not been squeezed 5 Engine flooded Set shift lever in neutral position Replace fuse refer ta page 97 Start by using starte rope refer to page 47 Engage the emergency Stop sw 1 refer page 15 and 19 Supply fuel eter puse 32 Open vent refer to page 38 aqueeze primer bulb 16 supply fuel Clean and dry spark plug refer to pape 91 6 OPERATION 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 fuil throttle are acceptable but do not operate the motor contin uously at full throttle Next 8 hours Avoid continuous full throttle oper ation 10096 throttle opening Do not run the outboard motor at full throttle for more th
74. wer trim tilt will not work FUSE RATING 15 Never usc a fuse with a different rating 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 15A FUSE _ i JALA SPARE 15 FUSE Replacement 1 Stop the engine 2 Remove the engine cover 3 Pull the blown fuse out of the clip 4 Push a new 15 fuse into the clip A spare 15 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 47 97 109 MAINTENANCE Propeller COTTER PIN stainless MARINE GREASE If the propeller is damaged replace it as follows a WARRING Before replacing the propeller remove the emergency stop switch clip to prevent accidan tal engine starting The propeller is thin and sharp To protect your hands wear the heavy gloves during replacement 98 S CASTLE NUT PLAIN WASHER SPECIAL SPLINE WASHER PROPELLER THRUST WASHER Removal Remove the cotter pin then remove the 16 mm castle nut 17 mm plain washer 10 mm special spline washer propeller and thrust washer COTTER PIN stainless Installation Install the thrust washer with the grooved side toward the gear case
75. witch 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 stern bracket no more than I or 2 tums counterclock wise 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 65 6 OPERATION POWER TRIM TILT TYPE a TILT LOCK LEVER Lock Lever Use the tilt lock lever when the boat is moored I Tilt the motor up as far as it will go using the power trim tiit switch 2 Move the tilt lack lever to the LOCK position and lower the outboard motor until the lack lever contacts the stern bracket refer 25 66 It may be necessary to lift the engine cover grip slightiy 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 OPERATION Trim Tab Adjustment TIGHTENING BOLT 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 unequal amount of effort is required to turn the boat right or left adjust the trim tab so that an equal amount
76. y 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 These outboard motors are certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or an oil 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 Marine dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging 15 misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 233 4 PRE OPERATION CHECKS Oxygenated Fuels Some conventional gasolines are being blended with alco hol or an ether compound These gasoline s are 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 itis unleaded

Honda Power Equipment BF40A/50A Boat User Manual

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